Inflatable medical devices

ABSTRACT

Inflatable medical devices and methods for making and using the same are disclosed. The devices can be medical invasive balloons, such as those used for transcutaneous heart valve implantation, such as balloons used for transcatheter aortic-valve implantation. The balloons can have high strength, fiber-reinforced walls.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional ApplicationNo. 61/363,793, filed 13 Jul. 2010; and 61/486,720, filed 16 May 2011,which are both incorporated by reference herein in their entireties.

BACKGROUND

1. Technical Field

Inflatable medical devices and methods for making and using the same aredisclosed. More narrowly, medical invasive balloons, such as those usedfor transcutaneous heart valve implantation are disclosed. For example,those balloons used for transcatheter aortic-valve implantation.

2. Description of Related Art

Inflatable structures, such as balloons, are widely used in medicalprocedures. A balloon is inserted, typically on the end of a catheter,until the balloon reaches the area of interest. Adding pressure to theballoon causes the balloon to inflate. In one variation of use, theballoon creates a space inside the body when the balloon inflates.

Balloons may be used in the heart valves, including during BalloonAortic Valvuloplasty (BAV) and Transcatheter Aortic Valve Implantation(TAVI). The balloons can be used to open a stenosed aortic valve. Astenosed valve may have hard calcific lesions which may tend to tear orpuncture a balloon. Additionally, a precise inflated balloon diametermay be desired for increased safety and control.

Balloons may be used to move plaque away from the center of a vascularlumen toward the vasculature walls, such as during an angioplasty or aperipheral vasculature procedure. During this procedure, a balloontipped catheter is placed in a vascular obstruction. As the balloon isinflated, the vessel constriction is dilated, resulting in improvedblood flow.

Two basic types of balloons are utilized: One is a high pressure,low-compliance balloon. The other is a lower pressure, high-complianceballoon.

High-compliance medical balloons are often composed of urethane, latex,silicone, PVC, Pebax, and other elastomers. As the pressure in ahigh-compliant balloon is increased, the balloon dimensions expand. Oncethe pressure is reduced, the high-compliance medical balloon may returnto its original shape, or near its original shape. High-compliancemedical balloons can easily expand several times in volume between zeroinflation pressure and burst.

Traditional high-compliance medical balloons can be inadequate for manyreasons. High-compliance, or highly elastic medical balloons typicallycannot reach high pressures because their walls have a low tensilestrength and their walls thin out as the balloon expands. In someinstances, high-compliance medical balloons provide insufficient forceto complete a procedure. Exceeding the rated pressure of ahigh-compliance medical balloon creates an excessive risk of balloonfailure which can lead to serious complications for the patient.

High-compliance medical balloons also have poor shape control. As ahigh-compliance medical balloon expands, it may assume a shape dictatedmostly by the particulars of the environment inside the patient ratherthan the clinical goals. In some cases, this can be contrary to what themedical practitioner desires. Many medical procedures are predicated onforming a particular balloon shape reliably.

High-compliance medical balloons often suffer from poor puncture andtear resistance.

Low-compliance, high pressure medical balloons substantially retaintheir shape under comparatively high pressures. PET (polyethyleneterephthalate) is the most common material for use in high pressurelow-compliance balloons. PET is commonly used for high-performanceangioplasty balloons. PET is stronger than other polymers, can be moldedinto a variety of shapes and can be made very thin (e.g., 5 μm to 50 μm(0.0002 in. to 0.002 in.)), thus giving these balloons a low profile.

Balloons made from PET walls are fragile and prone to tears. Whenpressed against a hard or sharp surface in the body, such as stenosis,PET balloons have poor puncture resistance. PET is very stiff soballoons made from PET may be difficult to pack or fold into a smalldiameter and may have poor trackability (i.e., the ability to slide andbend over a guidewire deployed through a tortuous vessel).

Balloons made from PET, while stronger than most other balloons madefrom homogenous polymers, may still not be strong enough to holdpressures sufficient to complete certain medical procedures.Additionally, with a large balloon diameter (For example, 20 mm orgreater), a PET balloon still has excessive compliance for proceduressuch as BAV and TAVI.

PET, like most low compliance balloons, is usually blow-molded. The blowmolding process makes it difficult or impossible to create certainshapes. Blow molding can result in wall thicknesses in the balloon thatdo not match the material thicknesses to the expected load.

Nylon balloons are an alternative material for low-compliance, highpressure balloons. These balloons are typically weaker than PET balloonsand so can contain less pressure. Nylon readily absorbs water, which canhave an adverse affect on Nylon's material properties in somecircumstances. Nylon has improved puncture resistance over PET and ismore flexible than PET.

A balloon is desired that can sustain high pressures, provide preciseshape control and be highly resistant to tear and puncture.

SUMMARY OF THE INVENTION

An inflatable medical device having a longitudinal axis is disclosed.The device has a balloon having a balloon length. The balloon has a walland an inflatable volume defined by the wall; wherein the wall comprisesreinforcement fibers; and wherein the reinforcement fibers are orientedsubstantially parallel with the longitudinal axis of the device; andwherein the reinforcement fibers have a reinforcement fiber length thatis less than about 75% of the length of the balloon length. Morenarrowly, the length of the reinforcement fiber can be less than about70%, yet more narrowly less than about 65%, yet more narrowly less thanabout 60% of the balloon length. All or substantially all of thereinforcement fibers in the balloon can have a reinforcement fiberlength of less than 70% of the balloon length.

The device can have a balloon having a balloon volume. The inflatablevolume can be the balloon volume.

The wall can have a first layer. The first layer can have at least twoof the reinforcement fibers. The first layer can have a polymer layer.

A composite fiber-reinforced medical balloon having a long axis is alsodisclosed. The balloon has an inner polymeric wall capable of sustainingpressure when inflated. The balloon also has a fiber and polymericmatrix outer wall. The outer wall has a layer of fibers and a polymerlayer. The outer wall surrounds and reinforces the inner polymeric wall.The fibers are high-strength, inelastic fibers. The layer of fibers hasat least a first fiber layer. All or substantially all of the fibers ofthe first fiber layer are less than about 75% of the length of the longaxis of the balloon and run substantially longitudinally along thelength of the long axis.

The fiber and polymeric matrix outer wall can have a second fiber layer.The fibers of the first fiber layer can run substantially perpendicularto the fibers of the second fiber layer when the balloon is uninflated.The fibers of the first fiber layer can remain substantiallyperpendicular to the fibers of the second fiber layer when the balloonis inflated.

The fibers of the second fiber layer can be wound radially around thelong axis of the balloon substantially over the entire length of thelong axis of the balloon.

The balloon can have minimal radial distension.

Also disclosed is an inflatable medical device having a longitudinalaxis. The device has a balloon that has a wall and an inflatable volumedefined by the wall. The wall has a first layer having reinforcementfibers. About 50% or more of the reinforcement fibers have separationsalong the lengths of the reinforcement fibers. At least about 25% of thereinforcement fibers in the first layer are parallel with each other.

The reinforcement fibers can be oriented parallel with the longitudinalaxis of the device. The reinforcement fibers can extend in two oppositedirections away from the separations. The separations can beintermediate along the length of the reinforcement fibers. Theseparations can be less than about 2 mm in length, more narrowly lessthan about 1 mm in length, yet more narrowly less than about 0.25 mm inlength.

The reinforcement fibers can have a first reinforcement fiber and asecond reinforcement fiber. The first reinforcement fiber can have afirst separation at a first length along the first reinforcement fiber.The second reinforcement fiber can have a second separation at a secondlength along the second reinforcement fiber. The first length can beunequal to the second length. The first reinforcement fiber can be theadjacent reinforcement fiber to the second reinforcement fiber. Thefirst reinforcement fiber can be parallel with the second reinforcementfiber.

Over about 90% of the reinforcement fibers can have separation along thelengths of the reinforcement fibers.

An inflatable medical device having a longitudinal axis and a load pathsubstantially parallel to the longitudinal axis is disclosed. Theinflatable medical device has a constant-diameter section disposedbetween taper walls and stem walls. The device has a balloon having awall and an inflatable volume defined by the wall. The wall has a firstlayer having reinforcement fibers. The reinforcement fibers aresubstantially parallel to the longitudinal axis. The load path from thedistal to the proximal end is interrupted in the constant-diametersection.

Also disclosed is an inflatable medical device having a longitudinalaxis and a load path substantially parallel to the longitudinal axis.The device has a constant-diameter section between taper walls and stemwalls. The device has a balloon having a wall and an inflatable volumedefined by the wall. The wall has a first layer having reinforcementfibers. The first layer has a first fiber and a second fiber. The firstand second fibers occupy the same load path.

The load path can be substantially parallel to the longitudinal axis.The distal end of the first fiber and the proximal end of the secondfiber can be located in the constant-diameter section. The first fiberand the second fiber can be located at the same angle as measured fromthe longitudinal axis, but at different lengths along the device.

An inflatable medical device is disclosed that has a longitudinal axis.The device has a constant-diameter section between taper walls and stemwalls. The device can be inflated and deflated, and when inflated has atensile load between the distal and proximal ends of the device. Thedevice has a first layer having reinforcement fibers. The reinforcementfibers are substantially parallel to the longitudinal axis and carry allor a substantial portion (e.g., over about 50%, or more narrowly overabout 75%) of the tensile load. A majority of the reinforcement fiberstransmit their entire tensile load as a shearing load to other fibers atleast at one point along the reinforcement fiber.

A majority of the reinforcement fibers can transmit their tensile loadas a shearing load to other fibers within the constant diameter section.The first layer can have a single layer of filaments.

Above about 66% of the force load within a single layer of fibers from aproximal terminal end or proximal cone of the device to a distalterminal end or distal cone of the device is carried as shear force atleast one point along the length. More narrowly, above about 70% of theforce load within a single layer of fibers from a proximal terminal endor proximal cone of the device to a distal terminal end or distal coneof the device is carried as shear force at least one point along thelength. Yet more narrowly, about 100% of the force load within a singlelayer of fibers from a proximal terminal end or proximal cone of thedevice to a distal terminal end or distal cone of the device is carriedas shear force at least one point along the length. The fibers can beunidirectional fibers.

The shear force can occur across load paths that are defined from aproximal terminal end of the balloon to a distal terminal end of theballoon. The shear force can occur in the fibers along the centrallength of the balloon (i.e., the length between a proximal cone and adistal cone, also referred to as the constant-diameter section).

The device can have a first fiber at the side of a first tow that canshear against a second fiber at the side of a second tow. The firstfiber can be immediately adjacent to the second fiber (i.e., with noother fibers between the first fiber and the second fiber).

Adjacent fibers within a single tow can shear against the fibers next tothem in the same tow.

A method is disclosed for making an inflatable device for use in abiological body. The method includes forming a leak-proof member, suchas a bladder, balloon or inflatable device, from first and second filmspositioned on a removable mandrel. The leak-proof member has a fiber.The first film has two panels. The first film is on the radially innerside of the fiber with respect to the inflatable device. The second filmhas two panels. The second film is on the radially outer side of thefiber with respect to the inflatable device. The forming includesperforating at least one of the panels.

The method can also include evacuating a fluid from between a perforatedpanel and a non-perforated panel.

Also disclosed is a method for making an inflatable device for use in abiological body. The method includes forming a leak-proof member byjoining films on a removable mandrel. The leak-proof member has a fiber.The method also includes perforating at least one of the films.

Another inflatable medical device for use in a biological body isdisclosed. The device has an inflatable balloon having a balloon wallhaving a reinforcement fiber. The balloon wall has perforations. Theballoon wall can be leak-proof. The perforations can extend through theballoon wall. The perforations may or may not extend through the balloonwall.

An inflatable medical device, such as a balloon, having a longitudinalaxis is disclosed that has an inner wall having a first seam orientedsubstantially parallel to the longitudinal axis of the balloon. Thedevice has a first and second fiber reinforcement layer. The device alsohas an outer wall having a second seam oriented substantially parallelto the longitudinal axis of the balloon.

The first and second fiber reinforcement layers can be radially outsidethe inner wall and radially inside the outer wall. The outer wall can beperforated. The first and second seams can lead from substantially theproximal to substantially the distal end of the balloon. The outer wallcan be perforated. The first and second seams can lead from a proximaltaper portion to a distal taper portion of the balloon.

Yet another inflatable medical device is disclosed. The device has aninner wall having a first and second seam oriented substantiallyparallel to the longitudinal axis of the balloon. The device has a firstand second fiber reinforcement layer. The device also has an outer wallhaving a third seam and a fourth seam oriented substantially parallel tothe longitudinal axis of the balloon.

The first and second fiber reinforcement layers can be radially outsidethe inner wall and radially inside the outer wall. The first and thirdseams can lead from substantially the proximal to substantially thedistal end of the balloon. The first and third seams can lead from theproximal taper portion to the distal taper portion of the balloon. Anyof the seams can be an angled seam between two split halves of therespective layer.

Another inflatable medical device for use in a biological body isdisclosed. The device has a fiber layer having one or more high-strengthsubstantially radiolucent filaments and one or more low-strengthsubstantially radiopaque filaments. The fiber layer has a first filamentlayer. The radiopaque filaments are located between the radiolucentfilaments in the first filament layer. The filaments can besubstantially parallel to each other. The filaments can be oriented in asubstantially circumferential pattern around the device. The filamentscan be oriented substantially in the longitudinal direction. The devicecan have a film on the radial outside of the fiber layer.

A method is disclosed for making an inflatable device for use in abiological body. The method includes applying a fiber layer bysimultaneously applying a high-strength radiolucent filament and alow-strength radiopaque filament. The fiber layer has a single filamentlayer. The radiopaque filaments are urged (e.g., laid down accordingly,pressed) to lie between the radiolucent elements.

An inflatable medical device is disclosed that has a high-strengthradiolucent fiber and a low-strength radiopaque fiber on separate layersare nested.

Also disclosed is a method of applying a fiber or filament tow to aballoon wall of a balloon having a longitudinal axis. The fiber tow hasfibers and/or filaments. The method includes delivering the fiber tow toa length of the balloon wall. The length of the balloon wall has anangle relative to the longitudinal axis of the balloon equal to orgreater than about 25°. The method also includes flattening the fibertow. Flattening includes spreading the fiber tow so the fibers orfilaments are side-by-side. The thickness of the tow after flatteningcan be equal to or less than about 25 microns. The flattened tow has atow width of less than about 250 microns.

The tow can have a circular cross-section before delivering the tow tothe balloon wall. The tow can be wound in a circumferential patternaround the balloon. The fibers or filaments can be in a substantiallysingle layer after the tow is applied to the balloon. Delivering the towcan include continually adding an adhesive to the fiber. Flattening caninclude increasing the adhesion of the tow to the wall.

A method of applying a fiber tow to a balloon wall of a balloon having alongitudinal axis is also disclosed. The fiber tow has fibers. Themethod includes delivering the fiber tow to a length of the balloonwall. The length of the balloon wall has an angle at an angled section,where the angle of the angled section relative to the longitudinal axisof the balloon equal to or greater than about 25°. The strain betweenthe topmost and bottommost fiber or filament in the fiber tow on theballoon wall angled section is less than or equal to about 2%. Thefibers or filaments are in a substantially single layer after beingapplied to the balloon.

The fibers or filaments can be applied to the layer by direct pressureby one or more direct pressure elements (e.g., a roller and/or jewel).The direct pressure element can be pressed against the fiber or filamentwith a spring loaded head. The fiber or filament can be spread normal tothe surface of the balloon, for example following the contour of theballoon. The balloon can be mounted on a mandrel. The mandrel can behard, solid, not hollow, or combinations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a variation of the device.

FIG. 1B illustrates a variation of cross section A-A of FIG. 1.

FIG. 2A illustrates a variation of the device.

FIG. 2B illustrates a variation of cross section QQ-QQ of FIG. 2.

FIGS. 3A, 3B, 3C, and 3D are cross-sectional views of a length ofvariations of the device.

FIG. 4A illustrates a variation of the device.

FIGS. 4B and 4C are variations of cross-section H-H of FIG. 4A.

FIG. 5 illustrates a variation of the device.

FIG. 6A illustrates a variation of the device.

FIGS. 6B and 6C are variations of cross-section D-D of FIG. 5A.

FIGS. 7A, 7B and 7C show close-up cross section views of variations ofthe seam.

FIG. 8A illustrates a variation of the device.

FIG. 8B is a variation of cross section E-E of the device of FIG. 8A.

FIG. 8C is a variation of cross section F-F of the device of FIG. 8A.

FIG. 8D is a variation of cross section G-G of the device of FIG. 8A.

FIGS. 8E and 8F illustrate variations of the device.

FIG. 9A illustrates a variation of the device in a deflated state.

FIG. 9B illustrates a variation of the device in an inflated state.

FIGS. 9C, 9C′, 9D, 9E, 9F, 9G, and 9H illustrate variations of thedevice.

FIGS. 9I and 9J are cross-sectional views of a portion of the wall ofvariations of the device.

FIGS. 9K and 9L illustrate variations of the device.

FIG. 10A illustrates a variation of the device in a deflated state.

FIG. 10B illustrates a variation of the device in an inflated state.

FIG. 11A illustrates a variation of the device.

FIG. 11B is a variation of cross section R-R of the device of FIG. 11A.

FIG. 12A illustrates a variation of the device.

FIG. 12B is a variation of cross section S-S of the device of FIG. 12A.

FIG. 13A illustrates a variation of the device.

FIGS. 13B and 13C are variations of cross section T-T of the device ofFIG. 13A.

FIG. 14A illustrates a variation of the device.

FIG. 14B is a variation of cross section i-i of the device of FIG. 14A.

FIGS. 15A and 15B are variations of the device

FIG. 16A illustrates a variation of the device.

FIGS. 16B and 16C are variations of cross section V-V of the device ofFIG. 16A.

FIG. 17A illustrates a variation of the device.

FIG. 17B is a variation of a cross section of the device of FIG. 17A

FIG. 18A illustrates a variation of the device.

FIGS. 18B, 18C and 18D are variations of cross-section X-X and Y-Y ofFIG. 18A.

FIG. 19A illustrates a variation of the device.

FIGS. 19B, 19C are variations of cross-section Z-Z and AA-AArespectively of FIG. 19A.

FIG. 20 illustrates a variation of the device.

FIGS. 21A and 21B illustrate a variation of the device in deflated andinflated configurations, respectively.

FIGS. 22A and 22B illustrate a variation of the device in deflated andinflated configurations, respectively.

FIGS. 23A-23E are partial see-through views of variations of the device.

FIGS. 24A, 24B, 24C and 24D illustrate variations of the device.

FIG. 25 illustrates a variation of the device.

FIGS. 26A through 26O are sectional views through variations of crosssection BB-BB of FIG. 1.

FIGS. 27, 28 and 29 are tables listing film materials, reinforcementmaterials, and adhesive and matrix materials, respectively.

FIG. 30A illustrates a variation of a tool for manufacturing a variationof the inflatable device.

FIG. 30B is a variation of cross-sectional view CC-CC of FIG. 30A.

FIG. 31 is a chart of material characteristics for variations of mandrelmaterials.

FIGS. 32A through 32E illustrate a variation of a method formanufacturing the device.

FIGS. 32F and 32G are transverse cross-sectional views of variations ofa bladder.

FIGS. 33A through 33D illustrate a method for manufacturing the device.

FIGS. 34A through 34I illustrate a method for manufacturing the device.

FIG. 35 illustrates a variation of a panel.

FIG. 36 illustrates a variation of a method for manufacturing thedevice.

FIG. 37 illustrates a variation of a method for manufacturing thedevice.

FIGS. 38A through 38E are transverse cross-sections of variations offiber tows in various configurations during a method of manufacturing.

FIGS. 39A through 39H illustrate a method of making a panel.

FIGS. 40A through 40C, 41A through 41B, 42A through 42B, 43A through 43Dand 44A through 44H illustrate variations of a panel.

FIGS. 45A through 45D illustrate a method for manufacturing the device

FIG. 46 illustrates a method for manufacturing the device.

FIG. 47A illustrates a method for manufacturing the device.

FIGS. 47B through 47G are cross-sectional views of variations of alayer.

FIGS. 47E through 47H are cross-sectional views of variations ofmultiple layers.

FIGS. 48A through 48D illustrate details of the manufacturing process inFIG. 47A

FIGS. 49A and 49B illustrate a method for manufacturing the device

FIGS. 50A and 50B illustrate variations of a panel.

FIGS. 51A through 51F illustrate a method for manufacturing the device

FIG. 52 illustrates a method for manufacturing the device.

FIGS. 53A and 53B illustrate a method for manufacturing the device

FIG. 54 illustrates a variation of a method for removing the mandrel.

FIGS. 55A through 55C illustrate a method for manufacturing the device

FIG. 56A illustrates a variation of the device in an inflated statebefore being pleated.

FIG. 56B illustrates a method of adding pleats or folds to a variationof the device.

FIG. 56C illustrates a variation of the device in a deflated, pleatedstate.

FIG. 57A illustrates a cross-section of a variation of the balloon wall.

FIG. 57B illustrates a cross-section of a variation of the ballooncontracted inside of a delivery tube.

FIG. 58 is a graph of compliance of the variation of the ballooncompared with a typical compliant balloon.

FIGS. 59 and 60 illustrate variations of a deployment tool with thedevice.

FIG. 61 illustrates a cross section of a human heart.

FIGS. 62A and 62B illustrate a variation of the device in deflated andinflated configurations, respectively.

FIGS. 63A through 63F illustrate a variation of a method for using thedevice.

FIGS. 64A through 64F illustrate a variation of a method for using thedevice.

FIGS. 65A through 65C illustrate a variation of a method for using thedevice.

DETAILED DESCRIPTION

FIGS. 1A and 1B illustrate that a medical inflatable device 2 can have aballoon 20 and a hollow shaft 2000. An inflation system (shown herein)can be attached to the hollow shaft to deliver a fluid pressure throughthe hollow shaft 2000 and to the balloon 20. The balloon 20 can beresilient (i.e., elastic) or non-compliant (i.e., inelastic). Theballoon 20 can have a balloon longitudinal axis 26. The balloon 20 canhave a balloon wall 22. The balloon wall 22 can define a cavity having aballoon volume 24. The balloon 20 can be a tube or a sheath. The tube orsheath can be a tubular structure that can be positioned over a medicaldevice, such as an endoscope, vasculoscope, colonoscope, arthroscope, orcombinations thereof. A tube can be a cylinder with a roughly equalinside and outside diameter. The balloon 20 can have a closed end (asshown in FIG. 2). The balloon 20 can have openings on either end (asshown in FIG. 1).

FIG. 1B illustrates that the balloon 20 can have a balloon length 28.The balloon length 28 can be from about 1.0 meter (39 in.) to about 5 mm(0.2 in.), more narrowly from about 200 mm (7.87 in.) to about 10 mm(0.4 in.), yet more narrowly from about 120 mm (4.72 in.) to about 50 mm(1.97 in) The balloon 20 can have a balloon proximal stem 30 having aballoon proximal stem length 32. The proximal stem length 32 can be fromabout 3.0 mm (0.12 in.) to about 15 mm (0.60 in.), for example about 10mm (0.40 in.). The balloon 20 can have a balloon proximal taper 34having a balloon proximal taper length 36. The balloon proximal taperlength 36 can be from about 0 mm (0 in.) to about 25 mm (0.98 in.), morenarrowly from about 10 mm (0.40 in.) to about 22 mm (0.87 in.), yet morenarrowly from about 16 mm (0.63 in.) to about 20 mm (0.79 in.).

The balloon 20 can have a constant-diameter section 38 having aconstant-diameter section length 40. The constant-diameter section 38can be the length between the balloon proximal taper 34 and a balloondistal taper 42. The constant-diameter section length 40 can be fromabout 0 mm (0 in) to about 55 mm (2.17 in), more narrowly from about 30mm (1.18 in) to about 50 mm (1.97 in). The constant-diameter section 38is referred to herein as “constant-diameter” for illustrative purposes,and the constant-diameter section 38 can have a constant or variablediameter along the length of the constant-diameter section 38. In thecase of a substantially variable diameter along the constant-diametersection, the constant-diameter section 38 is defined as the portion ofthe balloon between the cross sections of maximum balloon diameter.

The balloon 20 can have a balloon distal taper 42 having a balloondistal taper length 44. The balloon distal taper length 44 can be fromabout 0 mm (0 in) to about 25 mm (0.98 in), more narrowly from about 10mm (0.4 in) to about 22 mm (0.87 mm), yet more narrowly from about 16 mm(0.63 in) to about 20 mm (0.79 in). The balloon 20 can have a balloondistal stem 43 having a balloon distal stem length 45. The distal stemlength 45 can be from about 3 mm (0.12 in) to about 15 mm (0.6 in), morenarrowly about 10 mm (0.4 in).

The balloon 20 can have an inner lumen 154 a and an outer lumen 154 b.Inner lumen 154 a may be formed by second hollow shaft 2000 b. Innerlumen 154 a may provide a lumen thru the entire balloon 20. Inner lumen154 a may allow a guidewire to pass thru the interior of the balloon.Outer lumen 154 b may connect to balloon volume 24 and allow fluid intothe balloon volume 24. Placing fluid into balloon volume 24 may causethe balloon to inflate. Outer lumen 154 b may be formed between theinner wall of first hollow shaft 2000 a and the outer wall of secondhollow shaft 2000 b.

The proximal taper angle 90 b and the distal taper angle 90 a can befrom about 0 to about 90°, more narrowly about 50° to about 20°, yetmore narrowly about 45° to about 30°, for example about 40° or about 35°or about 30° or about 25° or about 20°. The proximal taper angle 90 band the distal taper angle 90 a do not need to be substantially thesame.

The balloon 20 can have one or more balloon fluid ports 56. The firsthollow shaft 2000 a can have a hollow shaft distal port 54. One of theballoon fluid ports 56 can attach to the hollow shaft distal port 54.

The balloon 20 can have a wall thickness 46. The wall thickness 46 canbe less than about 25 μm (1 mil). The wall thickness 46 can be fromabout 25 μm (0.98 mil) to about 250 μm (9.8 mil), more narrowly fromabout 50 μm (2 mil) to about 150 μm (5.9 mil), more narrowly from about35 μm (1.4 mil) to about 75 μm (3 mil), for example about 50 μm (2 mil),about 65 μm (2.6 mil), about 75 μm (3 mil), or about 100 μm (4 mil).

The balloon 20 can have a balloon inner diameter 48 and a balloon outerdiameter 50. The balloon outer diameter 50 can be measured perpendicularto the balloon longitudinal axis 26 at the widest point along the lengthof the balloon 20. The balloon outer diameter 50 can be from about 2 mm(0.08 in) to about 50 mm (2 in.) for example about 3 mm (0.12 in.),about 6 mm (0.24 in.), about 10 mm (0.4 in), about 17 mm (0.67 in.),about 20 mm (0.79 in), about 22 mm (0.87 in), about 26 mm (1.02 in), orabout 30 mm (1.18 in).

The balloon proximal stem 30 may have a diameter of 2 mm (0.08 in) toabout 50 mm (2 in.), more narrowly 2 mm (0.08 in) to about 5 mm (0.20in), for example about 2 mm (0.08 in), about 3 mm (0.12 in) or about 4mm (0.16 in).

The balloon 20 can have an unsupported burst pressure. The unsupportedburst pressure is the pressure at which the balloon ruptures wheninflated without any external constraint on the walls at about 1 atmexternal pressure and about 20° C. temperature. The unsupported burstpressure can be greater than about 150 psi (1,034 kPa). For example, theunsupported burst pressure can be from about 200 psi (1,379 kPa) toabout 1,500 psi (10,343 kPa). More narrowly, the burst pressure can befrom about 200 psi (1,379 kPa) to about 500 psi (3,448 kPa). Forexample, the burst pressure can be about 200 psi (1,379 kPa), 250 psi(1,724 kPa), about 300 psi (2,069 kPa), about 350 psi (2,413 kPa) about400 psi (2,758 kPa), or about 500 psi (3,448 kPa).

FIGS. 2A and 2B illustrate that the balloon 20 can have balloon length28. The balloon 20 can have a balloon proximal stem 30 having a balloonproximal stem length 32. The proximal stem length 32 can be from about 5mm (0.20 in) to about 15 mm (0.59 in). The balloon can have a balloonproximal taper 34 having a balloon proximal taper length 36. The balloonproximal taper length 36 can be from about 0 mm (0 in) to about 20 mm(0.79 in), more narrowly from about 0 mm (0 in) to about 15 mm (0.59in), yet more narrowly from about 5 mm (0.20 in) to about 10 mm (0.39in). The balloon 20 can have a constant-diameter section 38 having aconstant-diameter section length 40. The constant-diameter sectionlength 40 can be from about 0 mm (0 in) to about 15 mm (0.59 in), morenarrowly from about 0 mm (0 in) to about 10 mm (0.39 in). The balloon 20can have a balloon distal taper 42 at the terminal distal end 68 or tipof the balloon 20. The distal taper 42 can have a distal taper length44. The distal taper length 44 can be from about 0 mm (0 in) to about 14mm (0.55 in), more narrowly from about 2 mm (0.08 in) to about 9 mm(0.35 in).

The proximal and/or distal tapers 34 and/or 42 can be concave, convexand/or s-curves. For example, the proximal and/or distal tapers 34and/or 42 can have continuously varying angles with respect to theballoon longitudinal axis 26.

The balloon 20 can have one, two, three or more balloon fluid ports 56.The balloon 20 can have no through lumen. For example, the balloon 20can have no longitudinal through-lumen extending through the proximalterminal end 70 nor through the distal terminal end 68.

The balloon 20 can have a balloon inner diameter 48 and a balloon outerdiameter 50. The balloon outer diameter 50 can be measured perpendicularto the balloon longitudinal axis 26 at the widest point along the lengthof the balloon 20.

The balloon 20 can have a radius (i.e., half the diameter), for exampleabout 8.5 mm (0.33 in), and a distal taper length, for example about 8.5mm (0.33 in). The ratio of the distal end length to the radius can befrom about 2:1 to about 0:1, more narrowly about 1:1 to about 0.25:1.

The balloon 20 can have an unsupported burst pressure. The unsupportedburst pressure is the pressure at which the balloon ruptures wheninflated without any external constraint on the walls at about 1 atmexternal pressure and about 20° C. temperature. The unsupported burstpressure can be greater than about 150 psi. For example, the unsupportedburst pressure can be from about 1,400 kPa (200 psi) to about 10,000 MPa(1,500 psi). More narrowly, the burst pressure can be from about 3,500kPa (500 psi) to about 6,000 kPa (900 psi). For example, the burstpressure can be about 3,500 kPa (500 psi), about 5,200 kPa (750 psi),about 7,000 (1,000 psi), about 10,000 kPa (1,500 psi), or higher than10,000 kPa (1500 psi).

The balloon 20 can be non-compliant or inelastic. The balloon 20 canhave a failure strain of less than about 0.30, more narrowly less thanabout 0.20, more narrowly less than about 0.10, yet more narrowly lessthan about 0.05. A non-compliant balloon can have a failure strain ofless than about 0.30.

The failure strain of the balloon 20 is the difference between theballoon outer diameter 50 when the balloon 20 is inflated to 100% of theburst pressure and the balloon outer diameter 50 when the balloon 20 isinflated to 5% of the burst pressure (i.e., to expand from a deflatedstate without stretching the wall material) divided by the 100% pressurediameter.

For example, the burst pressure of the balloon 20 can be greater thanabout 3,500 kPa (500 psi) and have an outer diameter 50 of about 17 mmand a wall thickness 46 of less than about 100 μm with a failure strainof less than about 0.10, for example less than about 0.05.

Also for example, the burst pressure of the balloon 20 can be greaterthan about 200 psi (1,379 kPa) and have an outer diameter 50 of about 24mm and a wall thickness 46 of less than about 75 μm with a failurestrain of less than about 0.10, for example less than about 0.05.

The reinforced balloon wall 22 may have a high tear strength as comparedto traditional polymers. Tear strength can correlate to puncturestrength and toughness. For example, in a Mod Mil-C-21189 10.2.4 teartest, a specimen is created. That specimen has a width, a height, andthickness. A slit is made in the sample parallel to the width, mid-wayalong its height. The slit is then pulled to initiate tear at thecorners of the slit. The Mod Mil-C-21189 10.2.4 tear test givesresultant data in tensile pounds force (lbf). For the test to bemeaningful as a comparison between two material samples, the tear testshould be done on a thickness-comparable basis. A nylon 12 balloonmaterial at about 0.0055 in (140 μm) thickness failed the tear test at amean tensile load of 25 lbf (111 newtons). A variation of the balloonwall 22 of about 0005 in. (127 μm) wall thickness 46 can fail the sametear test performed on the nylon 12 balloon at a mean tensile value of134 lbf (596 newtons).

In an ASTM D-3039 tensile test, a nylon 12 material at 0.0055 in. (140μm) thickness, failed at a mean tensile load of 22 lbf (98 newtons). Theballoon wall 22 of about 0.005 in. (127 μm) wall thickness 46 can failthe same tensile test performed on the nylon 12 material at a meantensile value of 222 lbf (988 newtons).

The balloon wall 22 can have a high puncture strength. For example, whena balloon 20 is inflated to about 60 psi (414 kPa) and a 1 mm (0.040 in)gauge pin is driven into the balloon 20 at about 1 mm/sec (0.04 in/sec),the pin may need to exert more than 6 lbf (27 newtons) to puncture theballoon wall 22. A typical non-compliant polymer medical balloon mayfail at about 3 lbf (13 newtons).

FIG. 3A illustrates that the balloon 20 can have a constant wallthicknesses 46 along the length of the balloon 20. A wall proximal stemthickness 46 a can be substantially equal to a wall constant-diametersection thickness 46 c and the wall proximal taper thickness 46 b.

FIG. 3B illustrates that the balloon 20 can have a varying, such asincreasing and/or decreasing, wall thicknesses 46 along the length ofthe balloon 20. FIG. 3B illustrates that the wall constant-diametersection thickness 46 c can be substantially greater than the wallproximal stem thickness 46 a. The wall proximal taper thickness 46 b canbe less than the wall constant-diameter section thickness 46 c andgreater than the wall proximal stem thickness 46 a.

FIG. 3C illustrates that the wall proximal stem thickness 46 a cansubstantially greater than the wall constant-diameter section thickness46 c. The wall proximal taper thickness 46 b can be less than the wallproximal stem thickness 46 a and greater than the wall constant-diametersection thickness 46 c.

FIG. 3D illustrates that balloon 20 may terminate at the proximal end ofthe proximal taper 34. The balloon 20 may have no proximal stem 30.First hollow shaft 2000 a may have a flare 2004 that attaches to innerwall of proximal taper 34.

FIG. 4A illustrates that the balloon 20 can have a first balloonexternal seam 67 a and a second balloon external seam 67 b. Any or allseams 67 can extend partially, completely, not at all, or a combinationthereof, through the depth of the wall thickness 46. The balloonexternal seams 67 a and 67 b can be longitudinal seams (i.e., orientedin a longitudinal direction with respect to the balloon 20, parallel orat an angle to the longitudinal axis 26 of the balloon 20). The balloonexternal seams 67 a and 67 b can extend from a first lateral side of theballoon 20 at the proximal terminal end 70 of the balloon 20, along thefirst lateral side of the balloon to the balloon distal stem 43. Aballoon seam may be between 75% and 150% as long as the balloon length28, more narrowly between 85% and 125% as long as the balloon length 28.A balloon seam may be between 180% and 300% as long as the balloonlength 28, more narrowly between 190% and 260%.

FIGS. 4B and 4C illustrate that the balloon wall 22 can have one or morelayers 72. Each layer 72 can be a homogenous or heterogeneous discreteelement distinguished from other layers by radial distance along thethickness of the balloon wall 22. A layer 72 may comprise film,reinforcement material or adhesive or combinations thereof, for example,the materials listed in FIGS. 27, 28 and 29. The balloon 20 can have aleak-proof bladder 52. The bladder 52 can be defined by one or moreleak-proof layers within the balloon wall 22. The bladder 52 can befluid-tight, such as air-tight or saline tight, or can be a fluid-porousbladder. The bladder 52 can be made of a urethane, a nylon, any materiallisted infra (eg. the materials listed in FIG. 29), or combinationsthereof. The bladder 52 can be made from the radial inner-most layer 72b (as shown in FIGS. 4B and 4C) of the balloon wall 22. A bladder 52 maycomprise film, reinforcement material or adhesive or combinationsthereof (for example, the materials listed in FIGS. 27, 28 and 29).

The bladder 52 can be fixedly or removably attached to the hollow shaft2000, for example at the inside and/or outside diameter of hollow shaft2000. The hollow shaft 2000 can be a flexible or rigid catheter. Thehollow shaft 2000 can deliver pressurized fluid to the balloon volume24.

The balloon wall 22 can be made from panels 76. The panels 76 can, forexample, be cut or formed pieces of film and/or resin with or withoutother materials such as fibers. The layers 72 can each be made from oneor more panels 76. The panels 76 can each contain one or more layers 72,or multiple panels 76 (e.g., of the same material) can be formed into asingle layer 72, for example by melting panels 76 of the same materialinto an indiscrete, integral homogenous layer during the method ofmaking the device. A panel 76 or a panel 74 or a panel 196 may comprisefilm, reinforcement material or adhesive or combinations thereof (forexample, the materials listed in FIGS. 27, 28 and 29).

The outer layer 72 a of the balloon wall 22 can have an outer layerfirst panel 76 a and an outer layer second panel 76 b. The outer layerfirst panel 76 a can cover from about 90° to about 270° of the balloon,as measured in a transverse plane from the balloon longitudinal axis 26,for example about 185° of the balloon 20. The outer layer second panel76 b can cover from about 90° to about 270°, as measured along theballoon longitudinal axis 26, for example about 185°.

The balloon wall 22 can have one or more seams 66 and/or 67 and/or 69attaching panels 76 to other panels 76 in the same layers or to itself.The seams 66 and/or 67 and/or 69 can be an abutment or overlap of one ortwo panels 76 and/or panels 196 and/or panels 74. The seams 66 and/or 67and/or 69 can be linear, curved, circular, equatorial or combinationsthereof.

FIG. 4B illustrates that the balloon external seams 67 a and 67 b can beoverlayed seams, lap joints, or combinations thereof. The balloonexternal seams 67 a and 67 b can be flush against the side (i.e., havinga substantially constant radius with respect to the balloon longitudinalaxis 26) of the outer layer first panel 76 a or outer layer second panel76 b. The outer layer first panel 76 a can be radially outside of theouter layer second panel 76 b where the outer layer first panel 76 aoverlaps the layer second panel 76 b. The outer panels 76 may have anoverlap length 59. The overlap length 59 can be from about 0 mm (0 in.)(e.g., an abutment seam) to about 3 mm (0.12 in.), more narrowly fromabout 1 mm (0.04 in.) to about 2 mm (0.08 in.). The outer layer firstpanel 76 a can be bonded or adhered (e.g., with an adhesive) to theouter layer second panel 76 b. The adhesive can be an epoxy or athermally weldable material, such as a thermoplastic urethane.

The inner layer 72 b can have balloon internal seams 69 a and 69 b. Theballoon inner seams 69 a and 69 b can join an inner layer first panel 74a and an inner layer second panel 74 b. The inner seams 69 a and 69 bcan have a similar structure to those described here for the balloonouter seams 67 a and 67 b.

FIG. 4C illustrates that the outer layer first panel 76 a can be fused,solvated to, glued, adhered to, welded to, or a combination thereof,with the outer layer second panel 76 b at the outer seams 67A and 67B.An adhesive 208 may be placed between the first panel 76 a and thesecond panel 76 b at the inner seams 69 a and 69 b and the outer seams67 a and 67 b.

FIG. 5 illustrates that the balloon 20 can have a single balloonexternal seam 66 a. The seam 66 a can extend partially, completely, ornot at all through the depth of the wall thickness 46. The balloonexternal seam 66 a can be a longitudinal seam. The balloon external seam66 a can extend from a first lateral side of the balloon 20 at theproximal terminal end 70 of the balloon 20, along the first lateral sideof the balloon to the balloon distal terminal end 68. The balloonexternal seam 66 a can wrap around the balloon distal terminal end 68 a,extending around the distal end of the balloon 20 and returning on thesecond lateral side of the balloon 20.

The inner layer 72 b can have a balloon inner seam 66 b. The ballooninner seam 66 b can join an inner layer first panel 74 a and an innerlayer second panel 74 b. The inner seam 66 b can have a similarstructure to those described here for the balloon outer seam 66 a.

Sections C-C can be identical to variations of Sections H-H, except theouter seams 67 would be the single balloon external seam 66 a and theinner seams 69 would be the inner seam 66 b.

FIG. 6A illustrates that the balloon external seam 66 a can be a flangejoint. The outer layer first panel 76 a can have a seam first flange 80a around the perimeter of the outer layer first panel 76 a. The outerlayer second panel 76 b can have a seam second flange 80 b around theperimeter of the outer layer second panel 76 b. The seam first flange 80a can attach to the seam second flange 80 b at the balloon external seam66 a. The flange 80 can extend radially away from the balloonlongitudinal axis 26. The balloon external seam 66 a can be reinforced,for example with a metal foil, a wire or a polymer or combinationsthereof. The balloon external seam 66 a can be used to cut tissue duringuse in a biological target site or through tissue during delivery to thetarget site.

FIG. 6B illustrates that the seam first flange 80 a can be bonded oradhered to the seam second flange 80 b in the flange joint. FIG. 6Cillustrates that the layer first panel 76 a can be fused, solvated to,glued, adhered to, welded to, or a combination thereof, with the layersecond panel 76 b in the flange joint. An adhesive 208 may be placedbetween the first panel 76 a and the second panel 76 b at the seamsinner seam 66 b and the outer seam 66 a.

FIG. 7A illustrates that the balloon wall 22 can have a flange seam 66.The panels 76 a and 76 b can have seam areas 780. The seam areas 780 canbe located at the terminal edges and/or areas near the terminal edges ofpanels 76 a and 76 b in a plane in which the panels 76 a and 76 b lie.The seams 66 and/or 67 and/or 69 can join seam areas 780 of first panels76 to seam areas of adjacent second panels 76 in the same layer oradjacent layers to the first panels 76 a.

FIG. 7B illustrates that the balloon wall can have an abutment seam 66.The seam areas 780 can be perpendicular to the plane of the panels 76 aand 76 b.

FIG. 7C illustrates that the balloon wall can have a lap joint oroverlap seam 66. The seam areas 780 can be parallel to the plane of thepanels 76 a and 76 b.

FIG. 8A illustrates that the balloon external seam 66 a can be a lateralor latitudinal seam. The balloon external seam 66 a can be in a planeperpendicular or substantially perpendicular to the balloon longitudinalaxis 26. The balloon 20 can have one or more balloon external seams 66 aand/or 67.

The outer layer first panel 76 a can be at the distal end of the balloon20. The outer layer second panel 76 b can be at the proximal end of theballoon 20. The outer layer second panel 76 b can overlay the outerlayer first panel 76 a at the balloon external seam 66 a.

FIG. 8B illustrates that the outer layer first panel 76 a can overlaythe outer layer second panel 76 b at the balloon external seam 66 a.

FIG. 8C illustrates that the balloon wall 22 at a first length along theballoon 20 can have a first layer and a second layer. The first layercan be a radially inner layer 72 b, as measured from the balloonlongitudinal axis 26. The second layer can be a radially outer layer 72a. Any of the layers 72 can have a laminate of fiber and resin (e.g.,that can be elements of one or more panels 76 in the respective layers72). The resin can be an adhesive. The fiber and resin laminate can be amatrix of the fiber in the resin.

FIG. 8D illustrates that the balloon wall 22 at a second length alongthe balloon 20 can have first, second and third layers. The second layercan be a first middle layer 72 c between the inner and outer layers 72 band 72 a, respectively. Any combination of the layers can be leak-proof,reinforced with one or more fibers, resistant and releasable from MMA,or combinations thereof. The first middle layer 72 c can be reinforcedwith a fiber. The outer layer 72 a can be MMA-resistant and/orMMA-releasing.

An MMA-resistant material can substantially maintain material strengthand thickness when exposed to MMA bone cement in any stage of the MMAbone cement from mixing to curing. An MMA-releasable material can formno substantial bond with MMA.

FIG. 8E illustrates that the balloon external seam 66A can be positionedat the proximal taper 34 of the balloon 20. The balloon external seams66 a and/or 67 can be in the constant-diameter section 38, the distaltaper 42, the proximal taper 34, the proximal stem 30, or combinationsthereof.

FIG. 8F illustrates that balloon external seam 66 a can lie in a planeat a non-perpendicular angle to the balloon longitudinal axis 26. Theplane in which the balloon external seam 66 a lies can form a seam angle82 with the balloon longitudinal axis 26. The seam angle 82 can be fromabout 0° (i.e., a longitudinal seam) to about 90° (i.e., a latitudinalseam). More narrowly, the seam angle 82 can be from about 30° to about60°. For example, the seam angle 82 can be about 0°, about 30°, about45°, about 60°, or about 90°.

FIG. 9A illustrates that the balloon 20 can be pleated to form flutes84, for example four, five or six flutes 84, such as first flute 84 aand second flute 84 b. The flutes 84 can be made from accordion pleats,box pleats, cartridge pleats, fluted pleats, honeycomb pleats, knifepleats, rolled pleats, or combinations thereof. The pleating can be heatand/or pressure formed and/or the reinforcement fibers and/or panels canbe oriented to form the flutes 84. The balloon 20 can be in a deflatedconfiguration when the flutes 84 are shown.

FIG. 9B illustrates that the balloon 20 in an inflated configuration canpush the pleated flutes 84 radially outward to form a substantiallysmooth outer surface of the balloon wall 22. The balloon 20 can havereinforcement fibers 86. Longitudinal reinforcement fibers 86 b can besubstantially parallel with the balloon longitudinal axis 26.Latitudinal reinforcement fibers 86 a can be substantially perpendicularto the balloon longitudinal axis 26. Latitudinal reinforcement fibers 86a can be multiple fibers or a continuously wound single fiber. Theballoon 20 may have a load path 750.

The angle between fibers 86 a and 86 b may be approximatelyperpendicular and may not change between inflation and deflation.

FIG. 9C illustrates that latitudinal reinforcement fibers 86 a can beapplied in a wavy or curvy pattern (e.g., a sinusoidal configuration).FIG. 9C′ shows a close-up of the latitudinal reinforcement fiber 86 a.The wave pattern can have a first wave amplitude width 754 of less thanabout 10 mm (0.39 in), more narrowly less than about 5 mm (0.20 in),more narrowly less than about 2 mm (0.08 in). The wave pattern may havewave period width 758 of less than about 10 mm (0.39 in), more narrowlyless than about 5 mm (0.20 in), more narrowly less than about 2 mm (0.08in). When pressure is applied to the balloon 20 in 9C, the fibers 86 acan straighten to resemble the configuration of the fibers 86 a in FIG.9B.

During heating and consolidation of the balloon 20 during manufacture(for example, the process shown in FIGS. 55A, 55B and 55C), the fibers86 a may transform to a straighter configuration (e.g., the wave periodwidth 758 may increase and the first wave amplitude width 754 maydecrease). The balloon 20 can expand in the hoop direction withoutplacing the fibers 86 a in significant stress, for example, stress inexcess of 10% of the yield stress.

FIG. 9D illustrates that longitudinal reinforcement fibers 86 b can beapplied to the balloon 20 in a wavy or curvy pattern similar to thepattern of fiber 86A shown in FIGS. 9C and 9C′. Similarly, as describedsupra, during heating and consolidation of the balloon 20 duringmanufacture, the fibers 86 b may transform to a straighterconfiguration.

The latitudinal and longitudinal reinforcement fibers 86 a and 86 b on asingle balloon 20 can both have wavy configurations.

When inflated, the balloon 20 may have a biphasic compliance: a firstcompliance curve and a second compliance curve. The first compliancecurve may be generated as the balloon 20 is first pressurized and be theresult of the straightening of fibers 86 a and/or 86 b in the balloonwall 22. The second compliance curve may be generated by the strainingunder tension of fibers 86 a and/or 86 b which are then in asubstantially straight (e.g., not curvy) configuration.

For example, when the balloon volume 24 is initially inflated to atransition pressure of, for example, about 90 psi (610 kPa), thediametrical compliance of the balloon may average a first compliance ofabout 0.1% strain per psi (0.1% per 6.9 kPa). Therefore, when theballoon volume 24 is inflated to a transition pressure of 90 psi (610kPa), the balloon outer diameter 50 may have grown 9%. At pressuresbeyond the transition pressure of 90 psi (610 kPa), the compliance ofthe balloon may average a second compliance of about 0.015% per psi(0.015% per 6.9 kPa). Therefore, when the balloon volume 24 is inflatedto, for example, about 180 psi (1220 kPa), the balloon outer diameter 50may have grown 1.35% between about 90 psi (610 kPa) and about 180 psipsi (1220 kPa).

The transition pressure can be from about 15 psi (101 kPa) to about 1000psi (6890 kPa), more narrowly from about 15 psi (101 kPa) to about 250psi (1723 kPa), still more narrowly from about 15 psi (101 kPa) to about90 psi (610 kPa). The first compliance can be from about 0.025% per psi(0.025% per 6.9 kPa) to about 1% per psi (1% per 6.9 kPa), more narrowlyfrom about 0.05% per psi (0.05% per 6.9 kPa) to about 0.3% per psi (0.3%per 6.9 kPa). The second compliance can be from about 0.005% per psi(0.005% per 6.9 kPa) to about 0.05% (0.05% per 6.9 kPa), more narrowlyfrom 0.01% per psi (0.01% per 6.9 kPa) to about 0.025% per psi (0.025%per 6.9 kPa).

The balloon 20 can have uniphasic compliance. For example, the balloon20 may have no first compliance. The balloon 20 may have no secondcompliance. The balloon 20 may have no transition pressure.

FIG. 9E illustrates that first and second longitudinal reinforcementfibers 86 b and 87 b, respectively, can be substantially parallel withthe balloon longitudinal axis 26. The longitudinal reinforcement fibers86 b and 87 b can longitudinally overlap (i.e., have concurrentlongitudinal locations along the balloon 20) in reinforcement fiberoverlap area 612. The reinforcement fiber overlap area 612 may form ahoop-shaped area that partially or completely encircles theconstant-diameter section 38. The fibers 86B and 87B may have fiberlengths less than about 80% of the balloon length 28 more narrowly lessthan about 75% as long, more narrowly less than about 70% as long, stillmore narrowly less than about 65% as long, still more narrowly less thanabout 60% as long as the balloon length 28. Second or latitudinalreinforcement fibers 86 a can be substantially perpendicular to theballoon longitudinal axis 26.

FIG. 9F illustrates that the reinforcement fiber overlap area 612 mayform a spiral or helical-shaped area that partially or completelyencircles the constant-diameter section 38.

FIG. 9G illustrates that the fibers 86 b and 87 b can be separated byfiber separation areas 614. Fiber separation areas 614 may besubstantially rectangular and may have a fiber separation width 613 andfiber separation length 611. The fiber separation area 614 may separatefibers 86 b and 87 b by a fiber separation length 611 of about 2 mm(0.079 in.), more narrowly less than about 1 mm (0.039 in.), still morenarrowly less than about 0.25 mm (0.01 in.). The fiber separation areas614 may be distributed on the balloon surface such that no area 614longitudinally substantially overlaps any other area on the balloon 20.The fiber separation areas 614 may be distributed such thatlatitudinally adjacent fiber separation areas 614 do not have anylongitudinal overlap. The fiber separations 614 may be positioned alongthe length of the balloon 20 in a pattern sufficient to prevent anyfiber from reaching from a first terminal longitudinal end of theballoon 20 to a second terminal longitudinal end of the balloon 20. Asshown in FIG. 9G, the balloon 20 may have the panel 196 shown in FIG.40B, 40C or 41B. Fibers 86 b and 87 b may have fiber lengths 88 lessthan about 80% as long as the balloon length 28, more narrowly less thanabout 75% as long, more narrowly less than about 70% as long, still morenarrowly less than about 65% as long, still more narrowly less thanabout 60% as long as the balloon length 28.

FIG. 9H illustrates that the balloon 20 can have angled reinforcementfibers 85 a and 85 b. First angled reinforcement fiber 85 a and/orsecond angled reinforcement fiber 85 b can be at an angle with respectto the balloon longitudinal axis 26. For instance, first angledreinforcement fiber 85 a and/or second angled reinforcement fiber 85 bcan be from about 10° to about 60°. For instance, the fiber 85 a and/or85 b can be at about 10°, about 15°, about 20° or about 25° to theballoon longitudinal axis 26. The fiber 85 a can be at about 50°, about55° or about 60° with respect to the balloon longitudinal axis 26. Fiber85 b can have an equal but opposite angle to fiber 85 a. For example,fiber 85 a can be at +20 degrees and fiber 85 b can be at about −20° tothe balloon longitudinal axis 26. The balloon 20 can have one or morelatitudinal reinforcement fibers 85 c and/or longitudinal reinforcementfibers (e.g., 86 b and/or 87 b, not shown in FIG. 9H) with one or moreangled reinforcement fibers 85.

When inflated, the balloon 20 shown in FIG. 9H may have a biphasicdiametrical compliance: a first compliance curve and a second compliancecurve. For example, the balloon 20 may have a first angled reinforcementfiber 85 a that forms an angle of about 20° with the balloonlongitudinal axis 26 and a second angled reinforcement fiber 85 b thatforms an angle of about −20° with the balloon longitudinal axis 26. Thefirst diametrical compliance curve may be generated as the balloon 20 isfirst pressurized and be the result of the absolute value of the anglethat the fibers 85 make with the balloon longitudinal axis 26increasing. For instance the angles may change from about 20° to about39°, or from about −20° to about −39°. The balloon length 26 maydecrease and the balloon outer diameter 50 may increase, both inproportion to the pressure contained in balloon volume 24. The seconddiametrical compliance curve may be generated by the straining undertension of fibers 85 a and/or 85 b as the pressure in balloon volume 24is further increased. The first diametrical compliance curve may be morecompliant than the second diametrical compliance curve.

FIGS. 9I and 9J illustrate that the balloon wall 22 can have a firstload path 750 a, second load path 750 b a third load path 750 c, orcombinations thereof. The load path 750 may be a portion of the balloonwall 22. The load path 750 can have a load path width 762 and a loadpath length 766. For instance, the load path 750 may be bounded by thethickness of a layer of longitudinal fiber 86 b, have a load path length766 about as long as the constant-diameter length 40 and have a loadpath width 762 that encompasses one or a plurality of filaments 274 orreinforcement fibers 86 or combinations thereof. The load path length766 may be about parallel with the longitudinal axis 26 of the balloon20. A load path 750 may have one or more continuous fibers, one or morecut or separated fibers, or combinations thereof. Load path width 762may be about equal to fiber separation width 613

FIG. 9I shows that load paths 750 a, 750 b and 750 c may each contain acontinuous fiber 86 b. When balloon 20 is inflated, the fibers 86 b inthe load paths 750 may carry a tensile load along the longitudinal axis26.

FIG. 9J shows that load paths 750 a, 750 b and 750 c may each contain afirst longitudinal reinforcement fiber 86 b and a second longitudinalreinforcement 87 b. The first longitudinal reinforcement fiber 86 b canbe separated by the fiber separation area 614 from the secondlongitudinal reinforcement 87 b in the same load path 750. The tensileload in the respective load path 750 can be transferred by shearloading, as shown by arrows 770, from one load path to one or moreadjacent load paths, for example, from the second load path 750 b to theadjacent first and/or third load paths 750 a and/or 750 c, respectively;also for example from the first and/or third load paths 750 a and/or 750c, respectively, to the second load path 750 b.

When the balloon 20 is inflated, the reinforcement fibers 86 b and 87 bin the load paths may not carry a tensile load to between the two fibers86 b and 87 b, for example, because the fiber separation area 614 is inthe respective load path 750. The reinforcement fiber 86 b or 87 b maytransfer the respective fiber's tensile load via one or more shear loads770 to adjacent “receiving” reinforcement fibers 86 b and 87 b inadjacent load paths 750. The shear transferring of the tensile load cantension the adjacent receiving reinforcement fibers 86 b and 87 b. Forinstance, first shear load 770A may transfer tension from reinforcementfiber 87 b″ to reinforcement fiber 86 b′ over shear load length 772 a.Similarly, second shear load 770 b may transfer tension fromreinforcement fiber 87 b″ to reinforcement fiber 86 b′″ over shear loadlength 772 b.

About 20% or more of the longitudinal reinforcement fibers 86 b maytransmit their tensile loads as shear loads 770, more narrowly about 40%or more, still more narrowly about 60% or more, still more narrowlyabout 80% or more.

FIG. 9K illustrates that the reinforcement fiber 86 can be a singlecontinuous fiber wound (e.g., in a hoop wind) around the balloon 20. Thereinforcement fibers 86 can have a fiber density of about 100 winds perinch (i.e., the pitch of the wind). The pitch can vary across the lengthof the balloon 20. The balloon 20 can have a proximal pitch zone 618 a,a middle pitch zone 618 b, a distal pitch zone 618 c, or combinationsthereof. The reinforcement fiber(s) 86 in the pitch zones 618 a, 618 b,and 618 c can have the same or different pitches. For instance, thepitch of the fiber 86 in zone 618 b may be less than the pitches inzones 618 a and 618 c. The pitches in zones 618 a and 618 c may besubstantially equivalent. For example, the pitch in zones 618 a and 618c may be about 128 winds per inch, while the pitch in zone 618 b may beabout 100 winds per inch A lower pitch in one zone, such as middle zone618 b with respect to the other zones, such as the proximal and distalzones 618 a and 618 b, may force the balloon wall 22 to fail (if failureof the balloon wall occurs 22 at all) in the respective zone 618 bbefore failure of the balloon wall 22 were to occur in the other zones618 a and 618 c. In the example above, zone 618 b may burst duringfailure of the balloon 20 before zones 618 a and 618 c burst. The pitchzones with a lower pitch, such as middle zone 618 b, may be morecompliant than zones with a higher pitch, such as the proximal anddistal pitch zones 618 a and 618 b. The balloon 20 can inflate more inthe zone with the lower pitch, such as middle pitch zone 618 b, relativeto the zones with the higher pitch, such as the proximal and distalpitch zones 618 a and 618 b. One pitch zone (e.g., pitch zone 618 b) mayhave a 10% lower pitch than the remainder of the balloon wall 22 (e.g.,pitch zones 618 a and 618 c), more narrowly a 20% lower pitch.

FIG. 9L illustrates that the balloon 20 can have a proximal latitudinalreinforcement band 616 a and a distal latitudinal reinforcement band 616b. The pitch in the latitudinal reinforcement bands 616 may be higher orlower than the pitch of the latitudinal reinforcement fiber 86 a in theremainder of the balloon. For instance, the pitch in the bands 616 maybe at least 10% higher than the pitch in the remainder of the balloon,more narrowly 20% higher. Proximal latitudinal reinforcement band 616 amay begin at the proximal end of the constant-diameter section 38 andend in the balloon proximal taper 34. For instance, band 616 a may cover50% or 25% or 10% of taper 34. Similarly, distal latitudinalreinforcement band 616 b may begin at the distal end of theconstant-diameter section 38 and end in the balloon distal taper 42. Forinstance, band 616 b may cover 50% or 25% or 10% of taper 42. The hoopstrength of the balloon wall 22 in bands 616 may be increased over thehoop strength in the remainder of the balloon wall 22. The additionalstrength may minimize or stop balloon rupture propagation. For instance,if the balloon 20 were inflated and subsequently suffered a break inconstant-diameter section 38 in latitudinal reinforcement fiber 86 a, arupture might form that was substantially parallel to the longitudinalaxis. The resulting rupture may propagate into balloon proximal taper 34or balloon distal taper 42. However, bands 616 may server to stop thepropagation of the rupture because of their increased strength in thehoop or latitudinal direction.

A balloon 20 may be designed to burst in a certain mode. For instance,hoop fiber pitch may be chosen such that as pressure in increased inballoon volume 24, the balloon 20 will break fibers 86 a before breakingfibers 86 b.

FIG. 10A illustrates that the balloon 10 can be pleated to form flutes84, for example four, five or six flutes 84, such as first flute 84 a,second flute 84 b. The flutes 84 can be made from accordion pleats, boxpleats, cartridge pleats, fluted pleats, honeycomb pleats, knife pleats,rolled pleats, or combinations thereof. The pleating can be heat and/orpressure formed and/or the reinforcement fibers and/or panels can beoriented to form the flutes 84. The balloon 20 can be in a deflatedconfiguration when the flutes 84 are shown.

FIG. 10B illustrates that the balloon 20 in an inflated configurationcan push the pleated flutes out to form a substantially smooth outersurface of the balloon wall 22. The balloon 20 can have reinforcementfibers 86. Longitudinal reinforcement fibers 86 b can be parallel withthe balloon longitudinal axis 26. Latitudinal reinforcement fibers 86 acan be perpendicular to the balloon longitudinal axis 26.

FIGS. 11A and 11B illustrates the distal end of the balloon outer wall22 b can folded around (“everted”) and attached to the outside of thesecond hollow shaft 2000 b. The proximal end of the balloon outer wall22 b can folded around (“everted”) and attached to the outside of thefirst hollow shaft 2000 a.

FIGS. 12A and 12B illustrate that from the proximal end to the distalend, the balloon 20 can have a proximal taper 34, a first step 134 a, asecond step 134 b, a third step 134 c, and a distal taper 42, orcombinations thereof. The first step 134 a can have a first step outerradius 136 a. The second step 134 b can have a second step outer radius136 b. The third step 134 c can have a third step outer radius 136 c.The first step outer radius 136 a can be greater than or less than (asshown) the second step outer radius 136 b. The second step outer radius136 b can be greater than or less than (as shown) the third step outerradius 136 c. The first step outer radius 136 a can be greater than orless than (as shown) the third step outer radius 136 c.

During use, the increasing radii steps 134 can be used to measure thetarget site. The steps 136 may also be used to dilate a target site in apatient. The dilation may be done in succession, first using a step 134(for example, 134 a), next using a step 134 with a larger radius (forexample, 134 b). For example, the balloon can sequentially dilate astenotic vessel or valve with increasing known radii (e.g., instead ofpurely by feel) of dilation.

FIGS. 13A and 13B illustrate that the first step radius 136 a and thethird step radius 136 c can be substantially equal. The second stepradius 136 b can be less than the first step radius and the third stepradius.

FIG. 13C illustrates that a radially expandable implant 156 can beremovably attached to the balloon wall 22. For example, a stent, apercutaneous aortic heart valve, a replacement heart valve annulus, orcombinations thereof, can be balloon-expandable and deformed into thesecond step before insertion of the balloon into the target site.

FIGS. 14A and 14B illustrate that the balloon 20 can have a peanutconfiguration with a smaller diameter step 134 b between two largersteps 134 a and 134 c.

FIG. 15A illustrates that the balloon proximal stem 30, proximal taper34, constant-diameter section 38, distal taper 42, or combinationsthereof can be curved. The balloon longitudinal axis can be straight orhave a balloon radius of curvature 102. The balloon radius of curvature102 can be from about 2 mm (0.08 in) to about 50 mm (1.97 in), forexample about 5 mm (0.20 in), about 8 mm (0.31 in), about 15 mm (0.59in) or about 30 mm (1.18 in).

FIG. 15B illustrates that the balloon can have a C-shaped configuration.The balloon 20 can trace out an arc (e.g., a portion of a circle). Thearc can form an angle of 180 degrees or less, more narrowly 30-120degrees. The arc can form an angle of 30 degrees, 45 degrees, 60degrees, 90 degrees or 120 degrees.

FIGS. 16A and 16B illustrate that the balloon 20 can have a toroidal orannular shape. A fluid conduit 176 can extend from the hollow shaft 2000to the balloon 20. The fluid conduit 176 can delivery fluid pressure toinflate and deflate the balloon 20. The balloon 20 can have an innerwall 22 a and an outer wall 22 b. The inner wall 22 a can be radiallyinside the outer wall 22 b. The inner wall 22 a and/or the outer wall 22b can comprise a fiber 86 and/or a panel 196. The balloon 20 can have anannular lumen 160 passing through the radial center of the balloon 20.The annular lumen 160 can open to an annular lumen distal port 162 a andan annular lumen proximal port 162 b.

The distal end of the annular lumen 160 can be attached to one or moredistal tensioners 164 a. The distal tensioners 164 a can be elastic orinelastic wires, fibers or threads. The distal tensioners 164 a can befixed at distal tensioner first ends evenly or unevenly angularlydistributed around the distal end of the balloon 20. The distaltensioners 164 a can attach at distal tensioner second ends to a distaltension anchoring wrap 166 a. The distal tension anchoring wrap 166 acan be fixed to the hollow shaft 2000.

The proximal end of the annular lumen 160 can be attached to one or moreproximal tensioners 164 b. The proximal tensioners 164 b can be elasticor inelastic wires, fibers or threads. The proximal tensioners 164 b canbe fixed at proximal tensioner first ends evenly or unevenly angularlydistributed around the proximal end of the balloon. The proximaltensioners 164 b can attach at proximal tensioner second ends to aproximal tension anchoring wrap 166 b. The proximal tension anchoringwrap 166 b can be fixed to a tensioning collar 168.

The second step can form a waist. The waist can have additional hoopwrapped fibers. The waist can be substantially non-compliant. The waistcan be from about 0 mm (0 in) to about 12 mm in the balloon longitudinaldirection, more narrowly from about 3 mm to about 9 mm. The waistdiameter can be from about 2 mm (0.08 in) to about 35 mm, for exampleabout 3 mm, about 6 mm, about 20 mm, or about 23 mm.

The tensioning collar 168 can be slidably attached to the hollow shaft2000. The tensioning collar 168 can translate longitudinally, as shownby arrows in FIG. 16B, along the shaft. The tensioning collar can bepulled and/or pushed by a control line 170 or rod. Before deployment ofthe inflatable device and after deployment but before removal of theinflatable device, the balloon can be deflated and contracted againstthe hollow shaft. For example, the control line can be pulled to retractthe proximal end of the balloon. For example, the balloon can fold andcontract against the hollow shaft. The balloon may be pleated such that,when the tensioning collar is pulled or when a vacuum is applied tot theinflatable device, the balloon contracts into a small, packed form (notshown).

The balloon can have a distal segment 172 a and a proximal segment 172b. The distal segment 172 a and the proximal segment 172 b can beannular or toroidal. The annular or toroidal planes can be perpendicularto the balloon longitudinal axis 26. The distal segment 172 a can belongitudinally adjacent to the proximal segment 172 b. The distalsegment 172 a can be directly bonded to the proximal segment 172 b orjoined to the proximal segment 172 b by a segment joint 174. The segmentjoint 174 can be open and allow fluid communication between the proximalsegment 172 b and the distal segment 172 a (not shown) or can be closedto isolate the fluid volume or the proximal segment 172 b from the fluidvolume of the distal segment 172 a.

The distal segment and/or the proximal segment may be inflated by atube. The tube may be attached to the hollow shaft.

The outer wall, the inner wall, or both walls, may contain a radiopaquematerial as described herein.

The outer wall of the distal segment can form the first step. Thesegment joint can form the second step. The outer wall of the proximalsegment can form the third step. The second step can be radially smallerthan the first step and the second step. A device, such as a minimallyinvasive replacement heart valve can be attached to the outside of theballoon.

FIG. 16C illustrates that the balloon 20 can have a valve 178. The valve178 can have a first leaflet 180 a, a second leaflet 180 b, a thirdleaflet (not shown), or more. The leaflets 180 can be thin and flexible.The leaflets 180 can collapse inside the annular lumen 160 when theballoon is in a contracted configuration. The valve can allow flowthrough the annular lumen 160 in the distal direction and prevent flowthrough the annular lumen 160 in the proximal direction. The valve 178can be fixed to the distal end of the distal segment of the balloon. Theleaflets 180 can be oriented to allow flow distally through the annularlumen and impede or prevent flow proximally through the annular lumen.The leaflets 180 can be oriented to allow flow proximally through theannular lumen and impede or prevent flow distally through the annularlumen.

FIG. 17A illustrates that a shell 678 can have apertures 714. Theapertures may be located in the proximal taper 34 and/or the distaltaper 42. There may be an equal number of apertures on the each taper.The balloon could have 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or more apertureson each taper. The apertures may be aligned to fall between flutes orpleats. Apertures 714 may allow fluid, such as blood, to flow thru theinside of the shell. Apertures 714 may make the shell incapable ofsustaining static pressure. Shell aperture flaps 718 may be made so thatthey will close apertures 714 when there is no flow through the balloon.When flow proceeds from left to right in FIG. 17A with sufficientpressure, flaps 718 may open to allow flow through apertures 714. Whenthe pressure relaxes, flaps 718 may shut to restrict flow from right toleft in FIG. 17A. In this way, flaps 718 may act as a one way valve.

FIG. 17B shows a cutaway of an inflated annular balloon structure 682.Balloon segments 656 are compressed by shell 678. The annular balloonstructure has a central fluid passage 692 and apertures 714. Together,these features may allow fluids, such as blood, to pass through theannular balloon structure even when balloon segments 656 are fullyinflated. Second hollow shaft 2000 b may provide a lumen thru the centerof the balloon. This lumen may be used with a guidewire to locate theballoon during a medical procedure. Second hollow shaft 2000 b may havesome elasticity or compressibility in the axial direction. First hollowshaft 2000 a may allow the provision of pressurized fluid to hollowshaft distal port 54 and balloon inflation/deflation ports 654.Provision of pressurized fluid may cause balloon segments 656 toinflate. Removal of fluids may cause balloon segments 656 to collapseand for the shell to return to a pleated or fluted state.

FIG. 18A illustrates that the balloon can have segments that can beangularly adjacent to each other. For example, the segments and thesegment joints can be parallel with the longitudinal axis. The secondstep can have a larger radius than the first step or the third step. Theproximal and distal tensioners can attach to the segments and/or segmentjoints.

The segments may be inflated by a tube. The tube may be attached to thehollow shaft 2000. The distal and/or proximal tensioners can attach tothe balloon at the segment joints and/or at the segments.

The segment walls can have a radiopaque foil and/or a wire, such as aradiopaque marker wire.

FIG. 18B illustrates that the segments can be in fluid isolation fromeach other at cross section X-X. The segments can have a flattenedcircle longitudinal cross-sectional configuration. For example, thesegments can be almond or eye-shaped.

FIG. 18C illustrates that the segments can be in fluid communicationwith each other at a length along the balloon shown in Figure M1.

FIG. 18D illustrates that the segments can have a circular longitudinalcross-sectional configuration. For example, the segments can becylindrical.

FIGS. 19A and 19B illustrate that the balloon can have a constant outerdiameter when measured along the longitudinal axis. For example, theballoon can have a single step. The balloon can have an inner wall 22 a,an outer wall 22 b and segment joints 174. The segment joints 174 canconnect the inner wall to the outer wall. The segment joints 174 canminimize the inward radial collapse of the inner wall during inflation.

FIG. 19C illustrates that the hollow shaft can have an inner lumen 154 aand an outer lumen 154 b. The fluid conduit can be in fluidcommunication with the outer lumen and the balloon. The outer lumen candeliver pressure through the fluid conduit and to the balloon. The innerlumen can be a through lumen. The outer lumen can extend through thedistal proximal tip.

FIG. 20 illustrates that the balloon can have a spiral or helicalconfiguration. The spiral can have a first winding 182 a, a secondwinding 182 b, and more (e.g., five, as shown) windings. The firstwinding 182 a can be joined to the second winding 182 b at a windingjoint 184. The winding joint 184 can have an adhesive or a weld joint.The winding joint 184 can have a strip of elastic or inelastic materialattached to the adjacent windings. The balloon 20 can be formed from asingle continuous lumen.

Radiopaque foils, wires and any other radiopaque element or metalelement herein can be made from gold, platinum, platinum-iridium alloy,tantalum, palladium, bismuth, barium, tungsten, or combinations thereof.A radiopaque element may be a layer or a panel or a reinforcementelement or a film or combinations thereof.

A radiopaque element may be low strength. A low strength material canhave a tensile yield strength less than about 100 ksi (690 MPa), morenarrowly less than about 50 ksi (345 MPa), still more narrowly less thanabout 35 ksi (241 Mpa), still more narrowly less than about 25 ksi (172MPa). The addition of the radiopaque element may increase the burststrength of the balloon no more than an insubstantial amount (e.g., byless than about 15%, more narrowly by less than about 10%, still morenarrowly by less than about 5%).

A radiopaque element may be ductile. Ductility can be measured bymeasuring the reduction in area of a test sample when pulled until thesample is fractured. Ductile materials can have about a 30% or morereduction in area, more narrowly, about a 40% or more reduction in area,still more narrowly about a 50% or more reduction in area, still morenarrowly about a 70% or more reduction in area, still more narrowlyabout an 80% or more reduction in area. Ductile materials, as comparedto brittle materials, typically can be bent or folded with less chanceof fracturing at the bend.

Any of the balloon layers can have radiopaque dyes.

FIGS. 21A and 22A illustrate that the first flute 84A can have a firstvane 186 a. The second flute can have a second vane 186 b. The vanes 186can be radiopaque elements. The vanes 186 can be panels. The vanes 186can be embedded within or attached to the inside or outside of theballoon wall 22. All, some, one, or none of the flutes can have vanes.The vanes 186 can be reinforcements. For example, the vanes 186 can be alaminate, foil or wafer. The foil or wafer can be a plastic or metallisted herein, such as tantalum. The vane 186 can be strong enough tocut soft or hard tissue adjacent to the pleat. The vanes 186 can berigid or flexible. FIGS. 21B and 22B illustrate that in an inflated orexpanded configuration, the vanes 186 can lie flat along the wall.

A single radiopaque layer can encompass substantially the entire area ofthe balloon (as shown in FIG. 1, but with a radiopaque layer congruentwith the balloon 20). The radiopaque layer can be a single continuouslayer, for example as a deposition or (e.g., radiopaque) foil liningwith e.g. a deposition or foil of a metal such as listed herein.

The foil can be less than about 30 μm (0.0012 in) thick, for exampleless than about 20 μm (0.0008 in) thick, for example about 15 μm (0.0006in), about 12 μm (0.0005 in), about 10 μm (0.0004 in) or about 8 μm(0.0003 in) thick. Radiopaque foils can be cut or patterned by lasercutting, wire EDM, die cutting or deposition. The foils may be mountedto a removable backing before cutting such that a pattern of foils maybe easily applied during the balloon construction process.

The vanes 186 can cover the distal half of the balloon. The vanes 186can cover the proximal half of the balloon. The vanes 186 can overlap inthe longitudinal center of the balloon. A radiopaque foil can strengthenthe balloon wall 22.

The balloon 20 can have pleats or flutes between vanes or panels. Thevanes or panels can form the pleats or flutes. A panel or vane, such asa radiopaque foil, can minimize leaks from forming between fibers in theballoon during use.

FIG. 23A illustrates that the vanes 186 can be spaced evenly around theballoon longitudinal axis. The vanes can be radiopaque and/or echogenic.The vanes can be rectangular, triangular, circular, oval, orcombinations thereof. The vanes can be made of a metal foil. The vanescan be oblong having a major axis and a minor axis. The major axis canbe parallel with the balloon longitudinal axis.

FIG. 23B illustrates that the balloon can have first vanes 186 a spacedevenly around the balloon longitudinal axis. The balloon can have one ormore second vanes 186 b at the balloon distal terminal end.

FIG. 23C illustrates that the balloon can have a third vane 186 c at theproximal taper. The second and/or third vanes can partially orcompletely circumferentially envelope the balloon around the balloonlongitudinal axis.

FIG. 23D illustrates that the balloon can have marker spots 188 evenlyor unevenly distributed around the balloon. The marker spots 188 can beradiopaque and/or echogenic. The marker spots 188 can be circular, oval,square, triangular, rectangular, pentagonal, hexagonal, or combinationsthereof. The marker spots 188 can be in a layer of the balloon wall orattached to the inner or outer surface of the balloon wall.

23E illustrates that the balloon can have a marker wire 190 in a helicalconfiguration about the balloon longitudinal axis. The marker wire 190can be radiopaque and/or echogenic. The wires 190 can be electricallyconductive. The wires 190 can carry electrical current, for example forRF delivery, resistive heating, or combinations thereof. The marker wire190 can be in a layer of the balloon wall or attached to the inner orouter surface of the balloon wall 22.

FIG. 24A shows a pattern for a marker wire 190. Marker wire 190 may bewound around the balloon such that it partially covers the distal andproximal ends of the constant-diameter section 38 of the balloon 20. Theconstant-diameter section 38 may be the area of the balloon that isresponsible for most or all of the expansion done by the balloon 20 in apatient.

FIG. 24B shows a pattern for a marker wire 190. Marker wire 190 may bewound around the balloon on both the distal 42 and proximal tapers 34 ofthe balloon. The marker wire may be wound up to the distal and proximalborders of the constant-diameter section 38 without any substantialamount of the wire being placed in the constant-diameter section 38. Themarker wire may be wound in a helical pattern in both directions on theballoon or be wound in a single direction. The angle 191 between twolayers of marker wire may be less than 20 degrees, more narrowly lessthan 10 degrees, still more narrowly less than 6 degrees.

FIG. 24C illustrates that the balloon 20 can have a marker wire 190wrapped over approximately the entire length of constant-diametersection 38. The marker wire 190 may be centered on the constant-diametersection 38. The marker wire 190 may cover only a portion of theconstant-diameter section 38. For instance, the marker wire 190 maycover more than 70% of the constant-diameter section 38, more narrowlymore than 80%, still more narrowly more than 90%. The marker wire 190may cover a portion of the distal tapers 42 and proximal tapers 34. Forexample, the marker wire 190 may cover 100% of the distal tapers 42 andproximal tapers 34, more narrowly more than 50%, still more narrowlymore than 25%. The marker wire 190 may be a latitudinal reinforcementfiber 86 a.

FIG. 24D illustrates that the balloon can have a marker wire 190 wrappedover substantially the whole length of the balloon 20.

The marker wire 190 can be made of any radiopaque material listed supra.The material may be chosen to be highly ductile so that it can formwithout fracturing as the balloon is folded. The marker wire 190 may bea round or flat wire. For example, the marker wire 190 may be circularand about 6 μm (0.0002 in) to about 25 μm (0.001 in) in diameter. Themarker wire 190 may be a flat (or rectangular) wire about 6 μm (0.0002in) to about 18 μm (0.0007 in) thick and about 12 μm (0.0005 in) to 125μm (0.005 in) wide. For example, it may be about 12 μm (0.0005 in) thickand 75 μm (0.0015 in) wide.

The marker wire 190 can carry a tensile load. For example, the wire 190can have a 0.001 in. diameter and maintain a tensile load of 0.3 Nwithout yield or failure. The marker wire 190 can be low strength and/orductile as defined herein.

The vanes 186, the marker spots 188 and the marker wires 190 can be onthe inside of the balloon wall 22, the outside of the balloon wall 22,or within the balloon wall 22.

FIG. 25 illustrates that the balloon can have a resistive heatingelement 204 in a layer of the balloon wall or on the radial outside orradial inside of the balloon wall. The heating element 204 can have aresistive wire on a panel. The panel can be made from copper or anothermetal. The heating element 204, such as the resistive wire or panel, canbe connected to a heating lead 206. The heating lead 206 can extendproximally along the hollow shaft 2000. The heating lead 206 can beproximally connected to a controller and power source. The system canhave a heat control unit for controlling the level of energy delivery tothe resistive heating element 204. The heating element 204 can beseparated positive and negative electrodes on the balloon wall outersurface and contact the target site tissue directly, within the balloonwall, or on the radial inside of the inside surface of the balloon, orcombinations thereof. The heating element 204 can have a dielectricmaterial. Radiofrequency energy can be delivered across the dielectricmaterial of the heating element 204 to create ohmic heating in thetissue. The balloon 20 can be used to heat, cool (e.g., when the panelis a Peltier junction), emit RF power, or combinations thereof.

The heating element 204 can be substituted for or configured incombination with a UV-emitting element, visible light-emitting element,microwave-emitting element, ultrasonic-emitting element, or combinationsthereof. The heating element 204 can be replaced or configured with astrain gauge, a peltier junction or a temperature measuring device, orcombinations thereof.

The balloon can be used to treat abnormal mucosa in an esophagus, forexample by positioning the heating element near or in contact with theabnormal mucosa and delivering heat. The mucosal layer of the esophagealwall, for example the columnar epithelium, can be injured or ablated andmade necrotic with the balloon to normalize mucosa in the esophagus.

FIG. 26A illustrates that the balloon wall 22 at section BB-BB or atother sections taken through a single wall of the balloon can have alayer 72 that can have a fiber matrix. The fiber matrix can have one ormore monofilaments 274 and one or more resins. The resin can be aflexible adhesive 208. The flexible adhesive can remain flexible whencured or melted to form the medical inflatable device 2.

monofilament 274 can be a reinforcement fiber 85 a reinforcement fiber86 or reinforcement fiber 87. A reinforcement fiber can be a tow. A towmay contain one or more monofilaments. A fiber may contain one or moremonofilaments. The fiber matrix may have one, two or more monofilaments86 running substantially parallel to each other and embedded in aflexible adhesive 208. The substantially parallel monofilaments may bepositioned within the flexible adhesive such that they are touching eachother along their length. The substantially parallel monofilaments maybe positioned such that there is flexible adhesive separating each fiberalong its length.

FIG. 26A illustrates fiber array layer 72 having a layer width 210 incross-section. The layer width 210 can include a number of monofilaments274. The layer 72 can have a linear quantity fiber density measured, forexample, as the number of monofilaments 274 per unit of layer width 210.The linear quantity fiber density can be equal to or greater than about500 monofilaments 274 per inch, more narrowly equal to or greater thanabout 1000 monofilaments 274 per inch, more narrowly equal to or greaterthan about 2000 monofilaments 274 per inch, yet more narrowly equal toor greater than about 4000 monofilaments 274 per inch. For example, theliner quantity monofilaments 274 density can be from about 1,000monofilaments 274 per inch to about 2,000 monofilaments 274 per inch.

The fibers 86 or monofilaments 274 can be high strength and inelastic.The fibers may have a strain to failure of less than 10%, more narrowlyless than 5%. The fibers may have an ultimate tensile strength greaterthan 1.8 GPa (260 ksi), more narrowly greater than 2.4 GPa (350 ksi),still more narrowly greater than 2.9 GPa (420 ksi). The fibers can havea fiber or monofilament diameter 212, for example, from about 1 μm(0.00004 in.) to about 50 μm (0.002 in.), for example less than about 25μm (0.001 in.), more narrowly less than about 20 μm (0.0008 in.). Thehigh strength fibers may be radiolucent or radiopaque. Theunidirectional fiber-reinforced matrix can have the same or differentsizes and materials of fibers within the same unidirectionalfiber-reinforced matrix.

The fiber matrix layer 72 can have a layer thickness 216 from about 1 μm(0.00004 in.) to about 50 u μm (0.002 in.), more narrowly from about 8μm (0.0003 in.) to about 25 μm (0.001 in.), yet more narrowly from about10 μm (0.0004 in.) to about 20 μm (0.0008 in.)

FIG. 26B illustrates that the fiber density can be less than the fiberdensity shown in FIG. 26A. For example, the fiber density can be about500 fibers per inch.

FIGS. 26C and 26D illustrate that the monofilaments 274 or fibers mayhave a non-circular cross section. For instance, they may have arectangular or oval cross-section. The cross section of monofilament 274may have a fiber maximum height 1068 of, for instance about 5 μm toabout 20 μm and a fiber maximum width 1072 of, for instance, about 20 μmto about 500 μm. For example, the fiber or monofilament 274 can be about8 μm high and 25 μm wide. For example, the fiber or monofilament 274 canbe about 12 μm high and 50 μm wide.

FIG. 26E illustrates that the inner layer 72 b can have a fiber matrixhaving monofilament 274 in an adhesive 208. The outer layer 72 a canhave a polymer film, for example as shown in FIG. 27. The laminate showncan be a part of or the entire balloon wall 22.

FIG. 26F illustrates that the outer layer 72 a and the inner layer 72 bcan be polymer films, for example as shown in FIG. 27. In any variation,the polymer films can be the same or different polymers, or anycombination thereof. The first middle layer 72 c can be a fiber matrix.

FIG. 26G illustrates the outer layer 72 a, inner layer 72 b, firstmiddle layer 72 c and third middle layer 72 e can be polymer films, forexample as shown in FIG. 27. The second middle layer 72 d can be a fibermatrix.

Part or all of the balloon wall 22 can have a volumetric quantitativedensity of monofilaments 274 measured, for example, as the number ofmonofilaments 274 per unit of area. The area quantity monofilaments 274density can be equal to or greater than about 100,000 monofilaments 274per square inch, more narrowly equal to or greater than about 250,000monofilaments 274 per square inch, more narrowly equal to or greaterthan about 1,000,000 monofilaments 274 per square inch, yet morenarrowly equal to or greater than about 4,000,000 monofilaments 274 persquare inch. The area quantity of fiber can be about 25% of the area ofa wall cross section, more narrowly about 50%, more narrowly about 75%.

The ratio of the volume of the fiber matrix to the volume of themonofilaments 274 can be about equal to or greater than about 15%, morenarrowly equal to or greater than about 30%, more narrowly equal to orgreater than about 50%, yet more narrowly equal to or greater than about75%.

FIG. 26H illustrates that the outer layer 72 a, and inner layer 72 b canbe polymer films. The first middle layer 72 c and the second middlelayer 72 d can be fiber matrices. The first middle layer 72 c and thesecond middle layer 72 d can be positioned with the monofilaments 274substantially parallel to each other (as shown), substantiallyperpendicular to each other, or at an angle to each other.

FIG. 26I illustrates FIG. 26H with the monofilaments 274 in secondmiddle layer 72 d substantially perpendicular the monofilaments 274 infirst middle layer 72 c.

FIG. 26J illustrates that the outer layer 72 a, inner layer 72 b, secondmiddle layer 72 d, and third middle layer 72 e can be polymer films. Thefirst middle layer 72 c and the fourth middle layer 72 f can be fibermatrices.

FIG. 26K illustrates that the outer layer 72 a, inner layer 72 b, secondmiddle layer 72 d, third middle layer 72 e, fifth middle layer 72 g, andsixth middle layer 72 h can be polymer films, for example as shown inFIG. 27. The first middle layer 72 c, fourth middle layer 72 f andseventh middle layer 72 i can be fiber matrices.

FIG. 26L illustrates that the outer layer 72 a can be an MMA-resistantand MMA-releasing polymer film. The inner layer 72 b can be a leak proofbladder made from a polymer film, for example as shown in FIG. 27. Thefirst middle layer 72 c can be a fiber matrix, for example with thefibers oriented as longitudinal fibers. The second middle layer 72 d canbe a fiber matrix, for example with the fibers oriented as latitudinalor hoop fibers. The third middle layer 72 e can be a resin or adhesive.The fourth middle layer 72 f can be a radiopaque layer, such as a metalfoil.

FIG. 26M illustrates that the outer layer 72 a can be a polymer film,for example as shown in FIG. 27. The inner layer 72 b can be a leakproof bladder made from a polymer film, for example as shown in FIG. 27.The first middle layer 72 c can be a fiber matrix, for example with themonofilaments 274 oriented as latitudinal or hoop fibers. The secondmiddle layer 72 d can be a fiber matrix, for example with themonofilaments 274 oriented as longitudinal fibers. The third middlelayer 72 e can be a resin or adhesive. The outer layer 72 a may serve toisolate and protect the filaments 274. For example, the filaments may benever get closer than 12 μm, or 10 μm, or 8 μm or 6 μm or 4 μm or 2 μmto the outside surface of the outer layer 72 a. The outer layer 72 aand/or the inner layer 72 b may not melt when adhered to adhesive 208using processing methods describe herein.

FIG. 26N illustrates that the outer layer 72 a can be a polymer film,for example as shown in FIG. 27. Outer layer 72 a may have perforations782 as described infra. The inner layer 72 b can be a leak proof bladdermade from a polymer film, for example as shown in FIG. 27. The firstmiddle layer 72 c can be an adhesive 208. The second middle layer 72 dcan be a polymer film. The third middle layer 72 e can be a fibermatrix, for example with the monofilaments 274 oriented as latitudinalor hoop fibers. The fourth middle layer 72 f can be a fiber matrix, forexample with the monofilaments 274 oriented as longitudinal fibers andwith marker wire 190. The fifth middle layer 72 g can be an adhesive208.

FIG. 26O illustrates that the adhesive 208 in fifth middle layer 72 gmay fill in perforations 782 in outer layer 72 a. Fourth middle layer 72f may contain a rectangular marker wire 190.

Any of the polymer or fiber matrix layers can be leak proof, watertight, air tight, MMA-resistant, MMA-releasing, or combinations thereof.

Magnetic resonance visualization enhancement materials, such as magneticcontrast agents, can be added to the adhesive, the film or the fiber.The magnetic resonance visualization enhancement materials can enhancethe visualization of the balloon during an magnetic resonance imaging(MRI) procedure. For example, the magnetic resonance visualizationenhancement material can be gadolium, Omniscan, Optimark, ProHance,Magnevist, Multihance, or combinations thereof.

Any of the layers, for example the outer layer, can be tinted or dyed avisible spectrum color. For example, a pigment, coloring additive,dispersions or other coloring agents, such as an coloring additive fromPlasticolors (Ashtabula, Ohio) can be added to the adhesive, laminate orfiber before consolidation. A paint or coating can be added to a layersurface or to the outer surface of the balloon wall.

The color can be selected for branding, market differentiating, as anindication of the type of device, the size of the device, orcombinations thereof. For example, devices having a selected diameter,length, pressure rating, clinical indication or efficacy, other commonperformance metric, or combinations thereof, can be dyed a specificcolor (e.g., green for a first type of device, red for a second type ofdevice).

The layers can have one or more optical fibers. The fiber optic can be astrain sensor. The strain sensor can monitor the laminate's mechanicalstatus in real time. The fiber optic can guide light delivery into thebody. The fiber optic can visualize a target site (e.g., gather lightfrom the body to produce a visual image).

FIG. 27 illustrates polymer films from which panels 196 and/or panels 74and/or panels 76 and/or layers 72 can be made. The thickness of thepolymer films can be from about 2 μm (0.00007 in.) to about 50 μm (0.002in.), more narrowly from about 2 μm (0.00007 in.) to about 18 μm (0.0007in.), yet more narrowly from about 4 μm (0.00016 in.) to about 12 μm(0.0005 in.). Films may be metalized or coated to change their surfaceproperties. Metallization or coating may take place before or after afilm is formed. Films may be treated chemically or via plasma or viacorona treating or by combinations thereof in order to modify theirbondability, for example to make them easier to bond too.

FIG. 28 illustrates materials from which the reinforcement fibers 86 ormonofilaments 274 can be made. Reinforcement materials may be highstrength as described supra. The reinforcement fibers 86 may be a wireor wires. The wire may have chosen with very low strain to failure (forinstance, about 2%) or a high strain to failure (for instance, 10% orgreater). The wire may be annealed or tempered to adjust its mechanicalproperties. The wire may have a breaking strength of greater than about150 ksi, more narrowly greater than 250 ksi, still more narrowly greaterthan 400 ksi. The wire may be less than 25 μm in diameter. The wire maybe substantially rectangular and less than about 25 μm in thickness1068, more narrowly less than about 15 μm in thickness 1068 whenintegrated into the wall of the balloon. The ratio of the width 1072 ofthe wire to the thickness 1069 of the wire may be greater than or equalto about 3, more narrowly greater than or equal to about 5, morenarrowly greater than or equal to about 10. The density of the wire maybe greater than about 2.4 g/cm{circumflex over ( )}3, more narrowlygreater than about 6.9 g/cm{circumflex over ( )}3, more narrowly greaterthan about 15 g/cm{circumflex over ( )}3.

The reinforcement fiber or wire 86 may be substantially radiopaque whenused under a fluoroscope as part of a medical procedure in the humanbody. The physician may use an inflation medium, such as saline, whichis not radiopaque when inflating a balloon 20.

The reinforcement fibers or wires 86 may be coated. The coating may bean adhesive or otherwise increase adhesion of the fibers or wires 86.The coating may be a thermoplastic chosen from one of the materials (orcombinations thereof) listed in FIG. 29. The thermoplastic may be meltedas part of the process of applying reinforcement fibers 86 to a balloon20.

FIG. 29 illustrates that the adhesive 208 can be an elastomericthermoset material, an elastomeric thermoplastic material, an epoxy, acoating or a combination thereof. The adhesive can be selected from anyof the materials, or combinations thereof, listed in FIG. 29. The matrixcan have a resin and a fiber. The resin can be an adhesive.

Method of Manufacture

FIGS. 30A and 30B illustrate that the device can be partially orcompletely manufactured in a pressure chamber 219. The pressure chamber219 can be in a pressure chamber case 218. The pressure chamber case 218can have a case top 220 a separable from a case bottom 220 b. The casetop 220 a can have a case top port 222. The case bottom 220 b can have acase bottom port 224. The case top port 222 can be in fluidcommunication with the top of the pressure chamber 219. The case bottomport 224 can be in fluid communication with the bottom of the pressurechamber 219.

The case top can screw or otherwise tightly join to the case bottom. Thepressure chamber case can have one or more o-rings (not shown) in o-ringseats 226.

The pressure chamber can have a mandrel seat 228. The mandrel seat 228can be configured to receive a mandrel 230. The mandrel seat 228 canhave holes or pores. The holes or pores in the mandrel seat 228 canallow pressure from the case bottom port and the bottom of the pressurechamber to reach the top surface of the mandrel seat around the mandreland/or directly under the mandrel.

The mandrel 230 can have the inner dimensions of the balloon 20.

The mandrel 230 can be a water soluble mandrel. The mandrel 230 may bemade from a low melting point wax or metal, a foam, some collapsingstructure or an inflatable bladder. The mandrel 230 can be made from aeutectic or non-eutectic bismuth alloy and removed by raising thetemperature to the melt point of the metal. The mandrel 230 can be madefrom aluminum, glass, sugar, salt, corn syrup, hydroxypropylcellulose,ambergum, polyvinyl alcohol (PVA, PVAL or PVOH), hydroxypropyl methylcelluslose, polyglycolic acid, a ceramic powder, wax, ballistic gelatin,polylactic acid, polycaprolactone or combinations thereof.

FIG. 31 illustrates characteristics of bismuth alloys from which themandrel 230 can be made. The characteristics are characterized bymelting temperature (as shown in the third row of FIG. 31) of thebismuth alloy.

The mandrel 230 can be transparent or translucent to light and/or anelectron beam. The mandrel 230 can be hollow. The outside surface of themandrel 230 can be coated in a release agent. The mandrel 230 may bemolded, machined, cast, injection molded or combinations thereof.

The mandrel 230 can be in the mandrel seat 228 and a first panel 196 ato be formed into about half of the inner layer of the balloon wall 22can be placed between the case top 220 a and the case bottom 220 b. Thecase top can then be secured to the case bottom.

FIG. 32A illustrates that the outer surface of the mandrel 230 can havesome glue or first adhesive 208 a. The first adhesive 208 a can belocated around the perimeter of the first panel's 196 a contact areawith the mandrel. The first adhesive 208 a can be water soluble. Thefirst adhesive 208 a can be a sugar syrup. A panel 196 a may bepositioned over the mandrel. The panel 196 a may be a single layer ormultiple layers. For instance, the panel could be a layer of film (forexample, taken from FIG. 27) and meltable adhesive (for example, takenfrom FIG. 29). The panel 196 a can be positioned with film on the sidethat touches the mandrel and adhesive on the radially outer side. Thepanel 196A may be perforated as described infra. The panel may not becapable of sustaining pressure between the top and bottom of the panel.

FIG. 32B illustrates that a positive pressure can be applied to the top220 a of the pressure chamber (e.g., through the case top port 222)and/or a negative pressure or differential pressure or suction or vacuumapplied to the bottom 220 b of the pressure chamber (e.g., through thecase bottom port 224). The panel 196A can get sucked and/or pressed downand/or formed onto the mandrel 230. The first panel can be smoothlyfitted to the mandrel 230 and adhered to the mandrel at the firstadhesive 208A. Heat may be applied to panel 196 a before forming ontomandrel 230. Forming of one panel 196 a may be done more than once ondifferent sized mandrels before the panel 196 a reaches the form shownin FIG. 32B.

Forming of panel 196 a may also be accomplished with a mechanical die.The mechanical die may be heated and conform closely to the shape of themandrel 230. The mechanical die may have a shape similar to the mandrelseat 228.

The mandrel 230 and panel 196 a can be mounted into a trimming jig. Anyexcess portion of the first panel 196 a extending from the mandrel 230can be trimmed with a blade, with a laser, with a water jet cutter, witha die cut tool or combinations thereof. The trimming jig can cover themandrel 230 and the first panel 196 a attached to the mandrel. Severalpanels 196 a and/or layers 72 can be formed over the mandrel 230 andcut. The panels 196 a and/or layers 72 may be trimmed at the same timeor one at time.

FIG. 32C illustrates that the mandrel can have the excess area of thefirst panel 196A removed in preparation for attachment of the secondpanel 196 b.

FIG. 32D illustrates that a second adhesive 208 b can be applied to thefirst panel 196 a around the perimeter of the second panel's 196 bcontact area with the first panel 196 a. The second adhesive 208 b canbe an epoxy, urethane, a thermoplastic, a cyanoacrylate, a UV curingadhesive, or combinations thereof. The mandrel 230 can be seated in themandrel seat 228 with the first panel 196 a in the mandrel seat. Thesecond panel 196 b can be placed on the mandrel 230 as shown (upsidedown relative to the FIGS. 30A and 30B for illustrative purposes).

FIG. 32E illustrates that after the case top 220 a is secured to thecase bottom 220 b, the positive and/or negative pressures can be appliedto the pressure chamber as described infra. The second panel 196 b canbe smoothly fitted or pressure formed to or against the mandrel 230 andadhered to the first panel 196 a at the second adhesive 208 b. Adhesioncan be accomplished by the application of heat. The first and secondpanels (196A and 196B) can form the inner layer 72 b or bladder 52 ofthe balloon wall. The inner layer may be leaktight. The inner layer maybe capable of sustaining pressure. Multiple layers can be made byrepeating the method described infra. The pressure chamber can beheated, for example, to decrease the viscosity of and decrease themodulus of the panels.

FIG. 32F shows a cross section of 32E with the mandrel 230 omitted. Theprocess in FIGS. 32A thru 32E may be repeated on the part shown in FIGS.32E and 32F to produce the bladder 52 cross section shown in FIG. 32G.Panels 196 c and 196 d may be formed. Each panel may have an adhesive208 c and 208 d facing radially inward. Balloon third and fourthinternal seams 69 c and 69 d may be oriented about midway betweenballoons first and second internal seams 69 a and 69 b. The bladder 52may be leaktight.

FIG. 33A illustrates that a first panel 196 a can rest on top of thefemale mold half 378 a. (The first panel 196 a can be a see-throughpolymer for illustrative purposes. For example, the contours of the moldmay be seen.) The first panel 196 a can be a polymer, such as a nylon,PET, polycarbonate, urethane or those materials shown in FIG. 27 or anyother polymer that can be readily formed or combinations thereof. Thefirst panel can be about 0.002 inches (50 μm) thick, more narrowly about0.001 inches (25 μm), thick yet more narrowly about 0.0005 inches (12μm) inches thick.

FIG. 33B illustrates that the first panel 196 a can be formed to thecontours of mold. Molding could be via heat or vacuum or pressure orcombinations thereof.

FIG. 33C illustrates that the first panel 196 a can be lifted free ofthe mold half 378 a. The first panel 196 a can have a panel flat 390that did not enter the form of the female mold during forming. The panel196 a can be trimmed, for example in a trimming jig.

FIG. 33D illustrates that first and second panels (196 a and 196 brespectively) can have their flats 390 trimmed. The two panels can beclosed tightly around a mandrel 230 and a mandrel shaft 392. The panelscan then be bonded to each other at the seam 66 b where they overlap.The seam 66 b may connect all or some of the material that overlaps. Theseam 66 b may be leak tight to the passage or air and water. The bondingof the seam 66 and/or 67 and/or 69 may be caused by addition of anadhesive, by the application of heat, by the application of ultrasonicenergy, by use of a laser, by the application of radio frequency energy,by the application of pressure or by combinations thereof. A materialmay be added to the seam, for example to bond the seam. The material mayabsorb laser light to generate heat in the seam.

FIG. 34A shows a bladder 52. The bladder 52 may be a thin-walled,blow-molded balloon. The bladder 52 may have a wall thickness of lessthan about 0.001 inches (0.025 mm), more narrowly less than about 0.0005inches (0.0125 mm). The bladder 52 may have a constant of variable wallthickness along the length of the bladder 52 and/or around thecircumference of the bladder 52. The bladder 52 may form the inner wallof a balloon 20 and be leak-tight.

The inner volume of the bladder 52 may be filled with a mandrel material(types of mandrel material are described herein). The filling may be byinjection or by pouring or combinations thereof. The filling may occurafter the bladder 52 has been formed. The mandrel material may be choseto match the thermal expansion properties of the fibers 86.

FIG. 34B shows a cut 350 that may be made though the wall of the bladder52. The cut 350 may be a longitudinal cut running the entire length ofthe bladder 52. The cut 350 could be made mechanically (i.e., with aknife), with a laser, a water jet cutter, an ultrasonic blade a heatedblade or combinations thereof. The cut 350 may allow one side of thebladder 52 to be opened. The cut 350 in FIG. 34F may leave the bladder52 in one piece. The cut 350 can extend along a portion (e.g., from oneterminal end to a mid-point, or from a first mid-point to a secondmid-point), or the entire length of the bladder 52.

FIG. 34C shows a cut 350 through the bladder 52 at a cut angle 351. Cutangle 351 may be about 0° to about 70°, more narrowly about 0° to about50°, still more narrowly about 25° to about 45°. FIG. 34D shows a cut350 through the bladder 52. The cut 350 is a spiral, with a maximum cutangle 351. FIG. 34E shows a cut 350 through the bladder 52 at a cutangle 351 of 0°. The cut 350 may separate the bladder 52 into a firstdetached bladder portion 52 a and a second detached bladder portion 52b. The first and second detached bladder portions 52 a and 52 b can eachbe half of the bladder 52 or can otherwise together comprise thecomplete bladder 52. The first bladder portion 52 a can be symmetric orasymmetric with the second bladder portion 52 b.

Bladder portions 52 can also be formed separately and then joined asdescribed infra. For instance bladder portions 52 could be formed bythermoforming, injection molding, physical vapor deposition, dip moldingor combinations thereof.

FIG. 34F shows the bladder 52 in FIG. 34B after being fit over a mandrel230 (mandrel 230 is inside bladder 52 and not directly shown in FIG.34F). The bladder 52 may be made slightly larger in diameter and/orlonger in length than the mandrel 230 onto which the bladder 52 is fit.This may allow the bladder 52 to be re-assembled on the mandrel 230 withan internal seam 66 that may be sealed. FIG. 34F shows a longitudinalseam 66 running the length of the bladder 52. The seam 66 may be sealedwith adhesive, by fusing, by heating, with a solvent or combinationsthereof. The sealed bladder 52 may form the inner layer 72 b of aballoon 20 and be leak-tight. Seam 66 may be an external seam 66 a orinternal seam 66 b.

FIG. 34G through 34I illustrate the bladder 52 of FIGS. 34C, 34D, and34E, respectively, after being fit over a mandrel 230 (mandrel notshown). The first bladder portion 52 a can overlap at a lap joint oroverlap (as shown), abut at an abutment, or flange with the secondbladder portion 52 b at the seam 66.

FIG. 34G shows that an angled seam 66 may be formed when the bladder 52is reassembled on the mandrel 230. FIG. 34H illustrates that a spiralseam 66 may be formed when the bladder is reassembled on the mandrel230. FIG. 34I shows that a 90 degree seam 66 may be formed when thebladder is reassembled on the mandrel 230. The seam 66 may be sealed asdescribed supra.

FIG. 35 shows a panel 196. Panel 196 may be constructed of a thin filmsuch as those shown in FIG. 27. The thin film may be a thermoplasticwith a thickness less than about 20 μm, more narrowly less than about 15μm, still more narrowly less than about 10 μm, still more narrowly lessthan about 6 μm. Panel 196 may have a similar outline to the paneldescribed infra in FIG. 40.

FIG. 36 shows panel 196 applied to mandrel 230 (not shown). Distal caul260 a and proximal caul 260 b may be applied over the panel 196. Asdemonstrated in FIG. 53 the assembled parts may be placed in a vacuumbag and heated until panel 196 fuses into a leak-tight bladder 52. Thecauls 260 may be removed and the remainder of the balloon built on topof the bladder 52 and mandrel 230 as formed. As shown in FIGS. 34Athrough 34I, the bladder 52 may be cut such that the bladder 52 can beremoved from one mandrel 230 and placed on another mandrel 230. A seam66 may be formed. The bladder 52 may preferentially adhere to the cauls260 allowing for easier handling and subsequent placement of bladder 52.

FIG. 37 shows a panel 196 being wrapped onto mandrel 230. The panel 196may be wrapped onto the mandrel 230 such that each successive wrapslightly overlaps the previous wrap. Cauls 260 (not shown) may be placedover panel 196. The assembled parts may be placed in a vacuum bag,heated and processed into a bladder 52 as described herein.

A bladder 52 may be formed by deposition. For example, a metal such asgold (or other materials listed herein) may be deposited to form abladder 52. For example, a material such as parylene may be deposited toform a bladder 52.

A bladder 52 may be formed from a heat shrink tube. The tube may beformed in manufacture to fit the mandrel 230, blown out to size, thenplaced over the mandrel 230 and shrunk to fit the mandrel. Shrinking maybe accomplished by the application of heat.

FIG. 38A shows a cross section of a tow 270. A tow 270 may be or haveone or more reinforcement fibers 86. A tow 270 may have one or moremonofilaments 274. For example, the tow 270 may contain about 6, 25,100, 500 or 1500 monofilaments. The tow 270 may have a tow height 271and a tow width 272. The tow 270 may be approximately circular. Forexample, the tow height 271 and tow width 272 may be about 0.025 mm(0.001 in) to about 0.150 mm (0.006 in), more narrowly 0.050 mm (0.020in) to about 0.100 mm (0.040 in), more narrowly 0.075 mm (0.003 in). Thetow 270 may be loosely held together by a polymer finish (not shown).

FIG. 38B shows that tow 270 may contain a marker wire 190. Marker wire190 may be circular, as shown, and radiopaque. FIG. 38C shows that themarker wire 190 in tow 270 may be rectangular with dimensions asdescribed supra.

FIG. 38D shows the tow 270 after the tow 270 has been spread. The tow270 may be flattened or spread by passing the tow 270 through a closelyspaced set of rollers that form a narrow pinch gap. The tow 270 may bespread by pulling the tow 270 under tension over a set of rollers orpins. After spreading, the tow 270 may have a tow height 271 less thanabout twice the fiber height 1068, for example about the same as fiberheight 1068. The fiber height 1068 and fiber width 1072 may besubstantially unchanged after spreading. For example, the fiber width1072 and fiber height 1068 may be about 15 μm (0.0006 in), tow width 272may be about 210 μm (0.008 in) and tow height 271 may be about 15 μm(0.0006 in). The marker wire 190 is not shown in FIG. 38D but may bepresent after the tow 270 has been spread.

FIG. 38E shows the tow 270 from 38D after the tow 270 has had additionalprocessing to flatten the monofilaments 274. The monofilaments 274 maybe flattened by, for example, running the flattened tow 270 as shown inFIG. 38D through a precision rolling mill. The fiber width 1072 may beabout 25 μm (0.001 in). The fiber height 1068 may be about 9 μm (0.0004in). The tow height 271 may be about 9 μm (0.0004 in). The tow width 272may be about 350 μm (0.0014 in). The marker wire 190 is not shown inFIG. 38E but may be present after the tow 270 has been spread and thefibers flattened.

FIG. 39A illustrates that a layer of fiber matrix can be made on aroller 232. The roller 232 can be configured to rotate about a rolleraxle 234. The roller 232 may have a diameter from about 100 mm (3.9 in)to about 1,000 mm (39.4 in). The roller 232 may be made or coated withan anti-stick material such as a flouropolymer.

FIG. 39B illustrates that a releaser 236, such as a release layer, canbe placed around the circumference of the roller 232. The release layercan be a low friction film or coating. The release layer may be a thinand/or flexible flouropolymer sheet.

FIG. 39C shows that an adhesive 208 can be placed on the releaser ordirectly onto the roller 232 (e.g., if no releaser 236 is used). Theadhesive 208 may be a thermoplastic film. The adhesive 208 may be athermoset adhesive. The adhesive 208 may be a solvated thermoplastic orthermoset. The adhesive 208 may have a backing film, such as paper.

FIG. 39D shows the application of the reinforcement fiber 86 to theroller 232. The fiber 86 may be unwound from a spool (not shown) androlled onto the top surface of the adhesive 208. The fiber 86 maycontain one or more monofilaments 274. Before winding, the fiber 86 maybe infused or coated with an adhesive 208, a solvent, or both. Thecoating may be a thermoplastic. The fiber 86 may have been previouslyflattened as detailed supra. The fiber 86 may have a non-circular crosssection, such as a rectangle or an ellispse. Any coating or sizing onthe fiber may have been removed using a solvent. The fiber 86 may beplaced with a gap between each successive fiber wrap. The gap may beless than 200 μm (0.008 in), more narrowly less than 5 μm (0.0002 in). Aheat source or a solvent may be used to fix the fiber 86 to the adhesive208 (i.e., tack the fiber 86 in place on the adhesive 208), to melt orsolvate a material onto the release layer 236, to melt or solvate amaterial on the fiber 86 or combinations thereof. For example, aseparate resistive heater, a laser, a source of hot air, or an RF weldermay be used. A solvent such as methyl ethyl ketone or tetrahydrofuranmay be used. The fiber 86 can be wound with a pitch of 3000 to 30 turnsper 1 inch (25.4 mm). The pitch can be chosen based on the total size ofthe fiber 86 or tow 270 being applied and the chosen gap between eachsubsequent fiber 86 or tow 270 on the roller 232. Applications of asingle monofilament 274, which may be a wire, can have pitches fromabout 2000 to about 100 turns per 1 inch (25.4 mm).

FIG. 39E shows reinforcement fiber 86 on top of adhesive 208 on top ofrelease layer 236. FIG. 39E may show a cross section after the operationshown in FIG. 39D is performed.

FIG. 39F illustrates that the roller can be placed between a vacuum topsheet 238 a and a vacuum bottom sheet 238 b, for example in a vacuumbag. A vacuum seal tape 240 can surround the roller 232 between thevacuum bottom and top sheets 238 b and 238 a, respectively. Air can beremoved from between the vacuum top and bottom sheets 238 a and 238 band within the vacuum seal tape, for example by suction from a suctiontube 242. Inside and/or outside of the vacuum bag, the roller 232 can beheated, for example to melt or cure the adhesive 208. Roller 234 can beremoved from the vacuum bag, for example after melting or curing of theadhesive is complete.

FIG. 39G shows the removal of the panel 196. For instance, a cut may bemade substantially perpendicular to the fiber. The panel 196 may bepeeled away from the release layer. The panel 196 may be substantiallyfoldable and/or flexible.

FIG. 39H illustrates that the panel 196 of fiber matrix can be removedfrom the roller 232. For example, the panel 196 can be peeled off thereleaser 236. The panel 196 can be repositioned on the roller 232 atabout 90 degrees to the layer's previous angle and additionalreinforcement fibers 86 can be applied as shown in FIG. 39D. This mayresult in a panel 196 with fibers 86 running perpendicular to each other(e.g., a “0-90” layer, so called for the angle the two layers of fibermake with respect to each other). The panel 196 can be cut into asmaller panel. For instance, the panel 196 can be cut with a trimmingjig, a laser, a water jet cutter, a die cut tool, or a combinationthereof.

FIG. 40A shows that a panel 196 may have reinforcement fibers 86 boriented substantially parallel to panel longitudinal edge 332. Thepanel 196 can have a panel width 334. The panel width 334 can be aboutequal to the circumference of the balloon 20 in the constant-diametersection 38. The panel 196 can have a panel length 335. The panel length335 can be greater than the balloon length 28. The panel 196 can have apanel rectangular section 336 and one or more panel serrations 338 a,338 b and 338 c. Each panel serration 338 a, 338 b and 338 c can have aportion of the panel 186 that forms a portion of the stem 30 or 43 andtaper 34 or 44. Each serration 338 a, 338 b and 338 c can have aserration edge 339 a, 339 b and 339 c, respectively. The angle betweenthe serration edges 339 and a line parallel to the reinforcement fibers86 b can be a panel serration angle 340. The panel serration angle 340can be about 30°, about 20°, about 10°, or about 0°. A first panelserration 338 a can be substantially in line with a second panelserration 338 b. One or more fibers 86 b may run from the terminal endof the first serration 338 a to the terminal end of the second serration338 b.

FIG. 40B illustrates that longitudinal reinforcement fiber 86 b can beparallel with longitudinal edge 332. Second longitudinal reinforcementfiber 87 b can be parallel with the fiber 86 b. Fibers 86 b and 87 b canbe separated by fiber separation areas 614. The fiber separation areas614 may separate fibers 86 b and 87 b by about 2 mm (0.079 in), morenarrowly less than about 1 mm (0.039 in), still more narrowly less thanabout 0.25 mm (0.01 in). The fiber separation areas 614 may bedistributed on the panel such that no area 614 substantially overlapsany other area in the X and/or Y direction. The fiber separation areas614 may be positioned in the X and Y directions on the panel 196 in apattern sufficient to prevent any fiber from reaching all the way acrossthe panel rectangular section in the X direction. The balloon 20 in FIG.9G may be built in part with the panel 196 shown in FIG. 40B or 41B.Fibers 86 b and 87 b may have fiber lengths 88 less than about 80% ofthe balloon length 28 more narrowly less than about 75% as long, morenarrowly less than about 70% as long, still more narrowly less thanabout 65% as long, still more narrowly less than about 60% as long asthe balloon length 28.

FIG. 40C illustrates a magnified view of panel area of separations 818.Fiber separation areas 614 are located on fiber separation bands 617.Fiber separation bands are arranged parallel to the Y-axis and areseparated by fiber separation spacing 615. Each fiber separation areas614 may be rectangular and have a fiber separation width 613 oriented inthe Y-direction and a fiber separation length 611 oriented in theX-direction.

Load path 750 may have a load path width 762. The load path 750 may besubstantially aligned with fiber separation width 613 along the X axis.The load path width 762 may be about equal to the fiber separation width613. The upper edge of separation area 614 a may be substantially inlinewith the lower edge of separation area 614 b. The lower edge ofseparation area 614 a may be substantially inline with the upper edge ofseparation area 614 c. By substantially inline it is meant that theremay be an overlap between areas 614 of 0 mm (0 in.) to about 0.2 mm(0.008 in.).

There may be from 2 to 25 separation bands 617, more narrowly 4 to 12,still more narrowly, 6 to 10. There may be 7 separation bands 617. Fiberseparation width 613 may be from about 0.10 mm (0.004 in.) to about 2 mm(0.08 in.), more narrowly from about 0.2 mm (0.008 in.) to about 1.0 mm(0.04 in.), still more narrowly from about 0.3 mm (0.012 in.) to about0.75 mm (0.03 in.). Fiber separation spacing 615 may be from about 0.50mm (0.020 in.) to about 12.5 mm (0.5 in.), more narrowly from about 1.0mm (0.04 in.) to about 6 mm (0.24 in.), still more narrowly from about 2mm (0.08 in.) to about 4 mm (0.16 in.).

Shear load length 772 between load paths 750 will always be at leastabout 2 times separation spacing 615. During heating and consolidationof the balloon 20 during manufacture (for example, the process shown inFIGS. 55A, 55B and 55C), Separation areas 614 may allow the balloon 20to expand in the longitudinal direction without placing the fibers 86 bin significant stress, for example, stress in excess of 10% of the yieldstress.

FIG. 41A shows that a panel 196 can have a panel rectangular section 336and one or more panel serrations 338 a, 338 b and 338 c. Panel serration338 b can be oriented in the Y direction substantially midway betweenpanel serrations 338 a and 338 c. Panel serration 338 b can be orientedin the Y direction substantially closer to either panel serrations 338 aor 338 c. The longest reinforcement fiber length 88 in panel 196 may beless than 75% of the length of the balloon, more narrowly less than 70%of the length of the balloon.

FIG. 41B illustrates that first longitudinal reinforcement fiber 86 bcan be parallel with longitudinal edge 332. The second longitudinalreinforcement fiber 87 b can be parallel with first longitudinal fiber86 b. The first and second longitudinal fibers 86 b and 87 b can beseparated by the fiber separation areas 614. The fiber separation areas614 may be positioned in the X and Y directions on the panel 196 in apattern so the first and second longitudinal reinforcement fibers 86 band/or fiber 87 b have fiber lengths 88 less than about 80% of theballoon length 28, more narrowly less than about 75%, more narrowly lessthan about 70%, still more narrowly less than about 65%, still morenarrowly less than about 60% of the balloon length 28. A continuousfiber 86 may connect from a first terminal end of the panel 196 to thesecond terminal end of the panel 196, where the first terminal end ofthe panel 196 is in the opposite X direction of the second terminal endof the panel 196.

FIG. 42A shows that a panel 196 may have reinforcement fibers 85 a and85 b oriented at equal and opposite angles 341 to panel longitudinaledge 332. Angle 341 may be, for example, about 10°, about 15°, about 20°or about 25° to the panel longitudinal edge 332. Fibers 85 a and 85 bcan be at about 50°, about 55° or about 60° to the balloon longitudinalaxis.

FIG. 42B shows that the panel serration angle 340 can be about 0°.

FIGS. 43A and 43B show that a panel 196 can be made from two panels 196a and 196 b. Panels 196 a and 196 b can be overlapped in reinforcementfiber overlap area 612. The long axis of overlap area 612 may besubstantially perpendicular to the reinforcement fibers 86 b and 87 b.The panels can be joined with adhesive or by melting the adhesive in thefiber matrix. The panel 196 in FIG. 43A may be used to make the balloon20 shown in FIG. 9E

FIGS. 43C and 43D show that the long axis of reinforcement fiber overlaparea 612 can be at an angle 341 to the Y axis. For example, overlap area612 can be at an angle 341 of from about 0° to about 50° to the Y-axis,more narrowly from about 5° to about 45°, still more narrowly from about15° to about 40° to the Y-axis. The panel 196 in FIG. 44A may be used tomake the balloon 20 shown in FIG. 9F.

FIG. 44A shows a panel 196 similar to the panel shown in FIG. 40A.However, reinforcement fiber 86 b forms reinforcement fiber loop back774. The reinforcement fiber 86 b can make about a 180° turn at the loopback 774. Reinforcement fiber 86 b may be continuous through loop back774. Reinforcement fiber 86 b may have a continuous length longer thanpanel length 335.

FIG. 44B shows that a panel 196 may have a panel width about from about¼ to about 1/10 the circumference of the balloon 20, more narrowly fromabout ⅙ to about ⅛ the circumference of the balloon 20. Thecircumference of the balloon 20 may be balloon outer diameter 50multiplied by pi. A panel 196 may have a first panel serration 338 a andsecond panel serration 338 b.

FIG. 44C shows a variation of the panel 196 in FIG. 44B. Panel 196 mayhave fibers 86 b that are parallel to panel serration edge 339 withinthe panel serration 338. Fibers 86 b may end on the centerline of thelong axis of panel 196

FIG. 44D shows that panel 196 may contain reinforcement fibers 85 a and85 b arranged in a woven pattern. A woven pattern can have fibers 85 aand 85 b that alternately pass over and under each other.

FIG. 44E shows that the panel 196 may contain reinforcement fibers 85 ina braided configuration.

FIG. 44F shows that the panel 196 may contain reinforcement fibers 85 ofvarious lengths in random orientations, sometimes referred to as chopperfiber.

FIG. 44G shows that a panel 196 may contain a panel arc section 810 andpanel legs 800. In panel arc section 810, fibers 86 b may travel on aradius of the arc section 810. In the panel legs 800, fibers 86 b maytravel on a line parallel to the edge of the panel legs. First panel 800a may have a panel length 802 a from about 50% to about 100% of theconstant-diameter section length 40, more narrowly from about 60% toabout 80%. Second panel 800 b may have a panel length 802 b from about10% to about 50% of the constant-diameter section length 40, morenarrowly from about 20% to about 40%. The panel leg width may be about ⅓to about ⅙ of the balloon outer diameter multiplied by pi, morenarrowly, about ¼. The panel 196 shown in FIG. 44G may be applied to aballoon 20. The panel arc section 810 may substantially cover the taperof the balloon. Panel legs 800 may cover a portion of theconstant-diameter section 38. A second panel 196 as shown in FIG. 44Gmay be applied similarly on the opposite taper. The two panels mayinterleave, substantially covering the balloon outer wall 22 b.

FIG. 44H show that panel length 802 may be about 100% of theconstant-diameter section length 40. Panel serrations 338 may beappended. Panel serrations may be applied to a balloon taper asdescribed herein. The panel in FIG. 44H may substantially cover theballoon outer wall 22 b when applied to a balloon 20.

Panels 196 can be flattened. For instance, a panel 196 may be flattenedin an industrial press by applying pressure and, optionally heat. Apanel may be passed thru a precision pinch gap roller and flattened.Flattening may comprise changing the shape of monofilaments 274 (asshown in FIG. 38E) and/or redistributing with the panel some or all ofadhesive 208.

FIGS. 45A, 45B, 45C and 45D illustrate that a panel 196 may be appliedto a mandrel with none, one or more layers 72 on the mandrel 230. Thepanel 196 may be joined to layers 72 by the application of adhesive orby heat or by combinations thereof. The panel 196, when folded onto theshape of the mandrel 230 may give a substantially complete coverage ofthe mandrel 230 with minimal or no overlap of the panel 196. Panelrectangular section 336 may cover the balloon constant-diameter section38. Panel serrations 338 may cover proximal taper 34, distal taper 42,proximal stem 30 and distal stem 43.

FIGS. 45B and 45C show that a die 778 may be used to press the panel 196onto the balloon 20. The die 778 may be heated and the panel 196 maycontain a thermoplastic. The die 778 may melt the thermoplastic andadhere the panel 196 to the balloon 20. The die may be shaped to matchthe mandrel 230 shape. After attaching two serrations 338 (one serrationat each end of the mandrel 230. See FIG. 45C), the mandrel 230 may berotated about its longitudinal axis to advance the next set ofserrations 338 into place under the die 778. The die 778 may again presstwo serrations 338 into place on the balloon 20. Subsequent use of thedie in this manner may attach substantially the entire panel 196 toballoon 20.

FIG. 46 shows a method of attaching longitudinal reinforcement fiber 86b to balloon 20. A tool wheel 248 mounted to a tool arm 246 follows alongitudinal path on balloon 20. As the wheel 248 rolls, it presses intoplace tow 270. Adhesive (not shown) may be added to tow 270 beforeapplication so that tow 270 will stick to balloon 20. The tow may be cutwhen the tool wheel 248 reaches the end of the mandrel 230, the mandrel230 may be rotated about its longitudinal axis, and a second track ofreinforcement fiber 86B may be applied as shown in FIG. 46.

FIG. 47A illustrates that fiber 86 can be wound over the mandrel 230 orover balloon 20. The fiber 86 may be continuous or discontinuous. Themandrel can be rotated, as shown by arrow 252, about the mandrellongitudinal axis 250 or balloon longitudinal axis. The first spool 244a can be passively (e.g., freely) or actively rotated, as shown by arrow254, deploying fiber 86 (shown) or tow 270. Before or during winding,the fiber may be infused or coated with an adhesive, a solvent, or both.The coating may be a thermoplastic. A fiber distal end can fix to theballoon 20 or directly to the mandrel 230.

The fiber 86 a may be wound with a gap between each successive fiberwind. The gap can be less than about 200 μm (0.008 in), more narrowlyless than about 5 μm (0.0002 in).

The fiber 86 can be wound with a pitch of about 3000 to about 30 windsper 1 inch (25.4 mm). The pitch can be chosen based on the total size ofthe fiber 86 or tow 270 being applied to the part from first spool 244 aand the chosen gap between each subsequent fiber 86 or tow 270 on thepart. Applications of a single monofilament, which may be a wire, canhave pitches from about 2000 to about 100 turns per inch.

A tool arm 246 can be attached to a rotating tool wheel 248. The toolarm 246 can rotate and translate, as shown by arrows 256 and 258, toposition the tool wheel 248 normal to and in contact with the balloon20. A second tool wheel 248′ (attached to tool arm 246′) can have arange of motion sufficient to apply pressure normal to the surface of aballoon taper section.

The tool wheel 248 can press the fiber 86 or tow 270 against the balloon20 and spread the monofilaments 274 as shown in FIG. 47B. The tool wheel248 may help to adhere the tow 270 to the balloon, for example byapplying pressure and following closely the surface of the balloon. Thetool wheel 248 can be heated to soften or melt the material on thesurface of the balloon 20. Another heat source or a solvent may be usedto tack the fiber in place, to melt or solvate a material on theballoon, to melt or solvate a material on the fiber or combinationsthereof. A separate resistive heater, a laser, a UV light source, aninfrared light source, a source of hot air, or an RF welder may be usedwith our without the tool wheel 248 to attach the fiber. A solvent suchas methyl ethyl ketone or tetrahydrofuran or alcohol or combinationsthereof may promote adhesion of the fiber 86 and may be used with ourwithout the tool wheel 248. The tool wheel 248 can be made of or coatedwith a non-stick material. The tool wheel 248 may not rotate. The toolwheel 248 may comprise a hard surface, for example carbide.

A second spool 244 b may deploy marker wire 190 during a windingoperation. Second spool 244 b may also deploy a reinforcement fiber 85(not shown). Marker wire 190 (or reinforcement fiber 85) may be appliedsimultaneously with fiber 86 and/or tow 270 to the balloon. Marker wire190 may interleave with reinforcement fiber 86 to form a single fiberlayer on balloon 20, for example as shown in FIG. 47C. Marker wire 190may be deposited on top (for example, as shown in FIGS. 47E and 47H) orbellow another existing fiber layer.

The resulting layer deposited in FIG. 47 can have a layer thickness 216of from about 1 μm (0.00004 in) to about 50 μm (0.002 in), more narrowlyfrom about 8 μm (0.0003 in) to about 25 μm (0.001 in).

FIG. 47B illustrates that a hoop wind can deposit a layer 72 ofmonofilaments 274 side by side on the balloon 20.

FIGS. 47C and 47F illustrate that a hoop wind can deposit a layer 72 ofmonofilaments 274 side by side on the balloon 20 and that one of thosemonofilaments may be a marker wire 190

FIG. 47C shows that a radiopaque marker wire 190 or radiopaque filamentmay be located between first monofilament 274 a and second monofilament274 b. Monofilaments 274 a and 274 b may be deposited on subsequentwinds of one tow. That is, marker wire 190 may be between the successivewinds of one tow and occupy the same layer 72 as the monofilaments 274 aand 274 b.

FIGS. 47D and 47G illustrate that a hoop wind can deposit a layer 72 ofmonofilaments 274 side by side on the balloon 20 and that one of thosemonofilaments may be a marker wire 190 and that an adhesive 208 maysurround those monfilaments in the layer 72.

FIGS. 47E and 47H illustrate that a hoop wind can deposit a layer 72 cof monofilaments 274 side by side on the balloon 20 and may deposit asecond hoop wind layer 72 d comprising a marker wire 190. Layers 72 cand 72 d may comprise an adhesive 208.

Panels 196 may also be formed in the cross sectional configuration shownin FIGS. 47B-H.

FIG. 48A shows a close-up cross-sectional view of the fiber applicationprocess in FIG. 47. Tow 270 is herein shown to contain 6 monofilaments274 spread flat and being wound on a balloon taper angle 90. The towcontains a lowest monofilament 608 and a highest monofilament 610.Monofilaments 608 and 610 can be monofilament 274.

FIG. 48B shows a further magnification of the wind cross-section in FIG.48A. Monofilaments 608 and 610 spiral around the balloon taper. Singleturn distance 602 gives the distance between each instance of the fiberin cross section. Lowest monofilament 608 has a lowest monofilament windradius 604 a to the balloon longitudinal axis at a first position andlowest monofilament wind radius 604 b at a second position. The firstand second groups of fibers shown in cross section may correspond to asingle wind around the balloon. Similarly, highest monofilament 610 canhave a highest monofilament wind radius 606 a at a first position and ahighest monofilament wind radius 606 b at a second position.

Based on geometry, the radius 604 b is equal to radius 604 a+sin(angle90)*(distance 602). The “*” symbol denotes multiplication, the “/”symbol denotes division and the “sin” symbol denotes a sine operation.The average radius between the first position and the second position istherefore 604 a+sin(angle 90)*(distance 602/2). Finally, based onaverage radius, we can calculate an approximate monofilament length fromthe first to the second position of lowest monofilament 608 of2*pi*(radius 604 a+sin(angle 90)*(distance 602/2)). For example, themonofilament length for lowest monofilament 608 for a radius 604 a ofabout 2.000 mm a distance 602 of about 0.250 mm and angle 90 of about35.000 degrees is about 13.017 mm

If monofilaments are assumed to lay down flat in a single layer (asshown in FIG. 48), radius 606 a can be shown to be equal to radius 604a+(sin(angle 90)*(fiber diameter 212*(number of fibers−1))). Similarly,the average radius between radius 606 a and radius 606 b is thereforeabout equal to (radius 604 a+(sin(angle 90)*(fiber diameter 212*(numberof fibers−1))))+(sin(angle 90)*(distance 602/2)). With the averageradius we can calculate monofilament length. For example, themonofilament length for highest monofilament 608 for a radius 604 a of2.00 mm, a fiber diameter 212 of 25 μm, 6 fibers, a distance 602 of0.250 mm and an angle 90 of 35.00 degrees is about 13.47 mm

In the previous two examples monofilament length is calculated for thelowest and highest monofilaments in a given tow as 13.017 mm and 13.467mm, respectively. The highest monofilament would need to be about 3.5%longer than the lowest monofilament. Over long distances, themonofilaments cannot significantly slide longitudinally with respect toone another, the uphill monofilament would need to strain (change itslength) about 3.5%. High strength fibers typically have strains tofailure of less than about 5%. The lowest fiber can experience nostrain. The highest fiber can experience strain near the failure pointof the highest fiber. Alternately, the highest fiber can relieve thestrain by sliding down the curve. The fiber tow can transform from aflat 1×6 layer of fiber as shown in FIG. 48 to more of a bundle in whichthe tow 270 is significantly thicker than a single monofilament diameter(for example, the tow 270 shown in FIG. 38A). The difference in strainmay cause the tow 270 (or filaments in the tow) to pull away from theballoon and thus have poor adhesion.

At an instantaneous point in the wind of a tapered part wherein the towis spread to a single monofilament thickness, the difference in strainbetween the highest monofilament and the lowest monofilament is about:Strain=(C/R)*100%WhereC=(sin(angle 90)*(fiber diameter 212*(number of fibers−1)))R=radius of lowest monofilament 604 aNote that strain is a function of the sine of the angle, a linearfunction of the number of fibers. and that for larger R, the strain isfar less than for a small R.

The balloon stem 30 may have a small radius. Hoop winding may begin atthe stem 30, progress up the proximal taper 34 and continue in theconstant-diameter section 38. It may be desirable to minimize balloonproximal taper length 36 while minimizing strain in the tow 270.

FIG. 48C shows that a first angle 600 a may be used initially as thewind begins, for instance, at the proximal taper 34. A second angle 600b may be used after the diameter of the balloon has grown larger thanthe balloon stem 30 diameter. Second angle 600 b may be larger thanfirst angle 600 a. Additional angles may be used as the balloon diameterat the point of application of the tow 270 increases. These angles maybe chosen to keep the difference in strain between the highest andlowest monofilament at or below a certain value, for example less than4%, or less than 3%, or less than 2% or less than 1%. A curve 601 with acontinuously variable radius of curvature, as shown in 48D may be usedthat holds the difference in strain at or below a certain value, forexample less than 4%, or less than 3%, or less than 2% or less than 1%.

The flattened fiber tow width may be the fiber diameter 212 multipliedby the number of fibers. For instance, for a fiber diameter of about 17μm and 8 fibers, the fiber tow width may be about 136 μm. For instance,for a fiber diameter of about 17 μm and 12 fibers, the fiber tow widthmay be about 204 μm. For instance, for a fiber diameter of about 23 μmand 5 fibers, the fiber tow width may be about 115 μm. The fiber towwidth may be less than 300 μm, more narrowly less than 250 μm, stillmore narrowly less than 200 μm, still more narrowly less than 160 μm.

FIG. 49A illustrates that a fiber 86 a can be helically wrapped aroundthe balloon 20.

FIG. 49B illustrates that a fiber 85 a can be wrapped at an angle 132 tothe longitudinal axis. A second layer 85 b may be wound at equal andopposite angle. Fibers substantially parallel to the longitudinal axismay be omitted. Angle 132 may be less than about 75°, more narrowly lessthan about 60°, for example about 51°. Angle 132 may be about 40°, about35°, about 30°, about 25°, about 20°, or about 15°.

FIGS. 50A and 50B illustrate that a panel 196 may have perforations 782.A perforation 782 may be defined as a hole or absence in a panel 196 orgap between panels 196. A perforation 782 may be circular, elliptical,rectangular, substantially linear or combinations thereof. A perforation782 may be formed mechanically (for example with a sharp tool or with aroller covered in spikes that extend radially outward), with a laser, awater jet cutter, via photolithography or combinations thereof. Aperforation 782 may be formed by applying two or more panels with a gap.

FIG. 50A shows a panel 196 with substantially circular perforations 782.The perforations 782 may have a diameter of about 0.025 mm (0.001 in.)to about 3.0 mm (0.12 in.), more narrowly about 0.10 mm (0.004 in.) toabout 0.50 mm (0.02 in.), still more narrowly from about 0.10 mm (0.004in.) to about 0.25 mm (0.01 in.). The perforations may be placed on thepanel 196 in a pattern. The perforations may separated from each otherin the X direction by perforation X-axis gap 783 and perforation Y-axisgap 784. Gaps 783 and 784 may be about 0.10 mm (0.004 in.) to about 12mm (0.47 in.), more narrowly about 0.5 mm (0.02 in.) to about 6.0 mm(0.24 in.), still more narrowly about 1.0 mm (0.039 in.) to about 4.0 mm(0.16 in.). Gaps 783 and 784 may between columns (A column is line ofholes in the Y direction) and rows (A row is a line of holes in the Xdirection).

FIG. 50B shows a panel 196 with rectangular perforations 782 havingperforation width 786 and perforation length 790. Width 786 and length790 can be from about 0.025 mm (0.001 in.) to about 12 mm (0.47 in.),more narrowly from about 0.025 mm (0.001 in.) to about 6.0 mm (0.24in.).

Panel 196 may have a perforation density of about 10 to about 1000perforations 782 per square inch (per 645 square millimeters), morenarrowly about 25 to about 500, still more narrowly about 50 to about250.

Perforations 782 may pass thru one or more panels 196, one or morelayers 72 or thru the entire balloon wall 22.

FIG. 51A illustrates that the outer surface of balloon 20 may have aglue or first adhesive 208A. A panel 196 c may be positioned over themandrel. The panel 196 c may have a panel length 197 and a panel width199. The panel length 197 may be equal to or less than twice the balloonlength 28. The panel width 199 may be equal to or less than 4 times theballoon diameter 50. The panel 196 c may be a single layer or multiplelayers. For instance, the panel could be a layer of film and meltableadhesive 208. The panel 196 c can be positioned with adhesive on theside that touches the reinforcing fibers with the film facing radiallyoutwards. The panel 196 c may be perforated as described supra. Thepanel 196 c may not be capable of sustaining pressure between the topand bottom of the panel 196 c.

FIG. 51B illustrates that a positive pressure can be applied to the top220 a of the pressure chamber (e.g., through the case top port 222)and/or a negative pressure or suction or vacuum applied to the bottom220 b of the pressure chamber (e.g., through the case bottom port). Thepanel 196 c can get sucked and/or pressed down onto the balloon 20. Thefirst panel can be smoothly fitted to the partially built balloon andadhered at the first adhesive 208A.

Panel 196 c and/or 196 d may be adhered to balloon 20 by melting anadhesive in or on panel 196 c and/or 196 d. This melting can beaccomplished with light (for example, infrared), with hot air, with alaser, with UV light, via an RF welding process or by using a hot metalpart to iron the panel 196 c and/or 196 d into place. The panel 196 cand/or 196 d can be mounted into a trimming jig and trimmed as describedsupra.

FIG. 51C illustrates that the balloon can have the excess area or thefirst panel 196 c removed in preparation for attachment to the secondpanel 196 d.

FIG. 51D illustrates that a second adhesive 208 b can be applied to thefirst panel around the perimeter of the second panel's contact area withthe first panel. The second adhesive can be an epoxy, urethane, athermoplastic, a cyanoacrylate, a UV cure, or combinations thereof. Themandrel can be seated in the mandrel seat with the first panel in themandrel seat. The second panel 196 d can be placed on the mandrel asshown (upside down relative to the FIGS. 30A and 30B for illustrativepurposes).

FIG. 51E illustrates that after the case top 220 a is secured to thecase bottom 220 b, the positive and/or negative pressures can be appliedto the pressure chamber as described infra. The second panel 196 d canbe smoothly fitted or pressure formed to or against the balloon 20 andadhered to the first panel 196 c at the second adhesive 208 b. The firstand second panels (196 c and 196 d) can form the outer layer 72 a of theballoon wall. The outer layer may be leak-tight. The outer layer may becapable of sustaining pressure.

FIG. 51F illustrates that a perforated panel 196 may be applied to theballoon 20. Perforations 782 may have been formed on the panel 196before it was formed onto balloon 20 after it was formed onto balloon20. Perforations 782 may have changed size during a forming operation. Aperforated panel may have been formed with a second leaktight panel 196e to maintain differential pressure or suction or vacuum during forming.Panel 196 e may be not become part of the balloon wall 22.

Panels 196 may be made from films that are highly permeable. By “highlypermeable” it is meant that the panel has a nitrogen transmission rateof greater than 60 and a CO2 transmission rate of greater than 1000.More narrowly, Panels 196 may be made from films in which the panel hasa nitrogen transmission rate of greater than 200 and a CO2 transmissionrate of greater than 2000. Still more narrowly, Panels 196 may be madefrom films in which the panel has a nitrogen transmission rate ofgreater than 500 and a CO2 transmission rate of greater than 5000. Theunits of transmission rate are cc (at STP)/sq. meter atm-day (forexample, cubic centimeters at STP per square meter atmosphere-day). STPis 0 Centigrade and 1 atm. Normalized thickness is 0.5 mm (0.02″ in.).

The outer layer may be substantially smooth and homogenous. The outerlayer may completely encapsulate reinforcement fibers 85 and/or 86and/or 87 b and provide protection from catching or pulling or abrasionor damage of these fibers when in the body.

The outer layer (for example, layer 72 a) may perfuse a chemical, suchas a drug.

Any methods of adding a layer to the mandrel or previous layer can berepeated to add additional layers, such as an outer layer of anMMA-resistant film.

The mandrel and the layers, including the panels, strips, wires orfibers, rosette, or combinations thereof, can be adhered, heated and/orpressurized, for example, to melt solvate, or otherwise bond the layers,for example by creating molecular bonds and decreasing the viscosity andmodulus of the layers.

FIG. 52 illustrates that a panel 196 may be applied to a balloon 20 toform an outer layer 72 a. The panel 196 may be a film, such as thoselisted in FIG. 27. The panel 196 may applied in a manner similar to thatshown in FIGS. 45A-45D.

Methods described supra for forming bladders 52 can also be used to formthe outer layer 72 a. For example, FIGS. 33A-33D, FIGS. 34A-34I, FIG.35, FIG. 36 and FIG. 37 disclose methods for applying a bladder 52 to amandrel 230. These same methods may be used for applying an outer film72 a to a balloon 20.

A outer layer 72 a may be formed by deposition. For example, a metalsuch as gold (or other materials listed herein) may be deposited to formouter layer 72 a. For example, a material such as parylene may bedeposited to outer layer 72 a.

A outer layer 72 a may be formed from a heat shrink tube. The tube maybe formed in manufacture to fit the balloon 20, blown out to size, thenplaced over the balloon 20 and shrunk to fit the balloon. Shrinking maybe accomplished by the application of heat.

FIG. 53A illustrates that after the layers 72 of the balloon have beenassembled on the mandrel 230, a distal caul 260 a can be placed over thedistal end of the balloon. A proximal caul 260 b can be slid over themandrel and the proximal end of the balloon. The proximal caul 260 b canbe sealed to the distal caul 260 a. The cauls 260 can be made from aflouro-polymer. The cauls 260 can have thermoformed FEP with a 0.005 in(127 μm) initial thickness.

FIG. 53B illustrates that the assembly in FIG. 53A can be placed betweentop and bottom vacuum sheets 238 a and 238 b. Sheets 238 may be sealedto each other with vacuum seal tape 240 to form a vacuum bag. Theinterior of the vacuum bag can be heated. The vacuum bag can be insertedinside of an oven or autoclave. The layers of the balloon on the mandrelcan be thermally cured or melted, for example under from about 15 psi(103 kPa) to about 450 psi (3100 kPa) of pressure. The suction tube 242can suction the interior of the vacuum bag. For example the pressure inthe vacuum bag can be less than about 1.5 psi (10 kPa).

FIG. 54 illustrates that a wash tube 264 can be inserted into a mandrelwashout port 262. A dissolving or solvating fluid can be deliveredthrough the wash tube and into the washout port 262. The mandrel can beremoved by delivery of a fluid solvent such as water, alcohol or aketone. The solvent may be applied during the consolidation process suchthat the solvent melts or partially softens the mandrel and concurrentlypressurizes the bladder. The mandrel 230 can be removed by raising themandrel to a melting temperature for the mandrel. The mandrel 230 can beremoved by deflating the mandrel or by collapsing an internal structure.

FIG. 55A illustrates that the balloon before final consolidation 620 maybe placed in a balloon mold 622 containing a balloon pocket 624. Theballoon mold may be porous such that substantial amounts of gas may bedrawn from balloon pocket 624 thru the wall of balloon mold 622 and outinto the surrounding atmosphere. The balloon may have a tube placed inits inner volume that may extend out either end of the balloon 622 (notshown). The tube may be thin and very flexible. The tube may be asilicon rubber.

A coating may be sprayed into mold 622 that bonds to the balloon duringcure and forms an outer layer 72 a on the balloon 20.

FIG. 55B illustrates that the balloon mold may be closed around theballoon 620. Pressure may be applied thru balloon second fluid port suchthat the balloon expands to contact the inside of balloon pocket 624.Alternately, the tube extending out either end of the balloon (notshown) may be pressurized to force the balloon into contact with pocket624.

FIG. 55C shows Pressure P inside the balloon volume 24 pressing theballoon wall 22 outwards. Mold 622 may be placed in an oven and heated.Mold 622 may have built in heaters. The balloon mold may be placed undervacuum (as per FIG. 53B) or placed in a vacuum chamber during heating.

Heating the balloon under pressure may cause one or more layers to meltand fuse with adjoining layers. The melting under pressure may removevoids in the balloon wall. The outer inner and outer film may not melt.Heating the balloon under pressure may cause the walls of balloon beforefinal consolidation 620 to fuse or laminate into one continuousstructure. The balloon outer wall 22 b and/or outer layer 72 a may besubstantially smoothed by this process. The balloon outer wall 22 band/or outer layer 72 a may be permeable or perforated such that gas orother material trapped in the balloon wall 22 during manufacture mayescape when the balloon is heated under pressure.

The final balloon outer diameter 50 may be very accurate and repeatable.For instance, at a given pressure, the outer diameter of a group ofparts may all fall within about 2% (+/−1%) of each other. For instance,if the nominal dimension of the outer diameter 50 of the balloon isabout 24 mm (0.945 in) at about 60 psi (414 kPa) all parts may have anouter diameter of about 23.76 mm (0.935 in) to about 24.24 mm (0.954in).

FIG. 56A illustrates that a pleated balloon 20 in an expanded orinflated configuration can be substantially circular in cross-section.

FIG. 56B illustrates that a balloon can be clamped in a pleating tool266 with two, three, four, five or more removable pleating blocks 268.Heating the pleating blocks 268 to about 80 C and then pressing themagainst the balloon for about 1 minute causes the balloon to becomepleated or fluted. Commercial pleating machines such as balloon foldingmachinery from Interface Associates (Laguna Niguel, Calif.) can also beused. A small amount of wax may be used to hold the pleated and foldedballoon into its desired shape.

FIG. 56C illustrates that a pleated balloon in a deflated or contractedconfiguration can have one or more pleats or flutes 84. The balloon 20may reform these pleat after inflation when vacuum is applied to balloonvolume 24.

Additional laminates can be added to areas of a balloon that mightrequire extra strength for certain procedures or uses. A balloon mayhave different amounts of fiber, adhesive or polymer film in differentportions of the balloon wall. A balloon may have different number offiber layers in different portions of the balloon wall.

Method of Use

The device 2, for example including the balloon 20, can be used forKyphoplasty, angioplasty including CTO dilation, stent delivery,sinuplasty, valvuloplasty, drug or other fluid delivery through theballoon, radiopaque marking, incising the inside of a vessel (e.g., toopen or expand a vessel), brachytherapy, intentionally obstruct avessel, or combinations thereof. The device 2 can be used to deliver oneor more stents and/valves and/or emboli filters to the coronary bloodvessels (e.g., arteries or veins), carotid artery, peripheral bloodvessels, the GI tract, the biliary ducts, the urinary tract, thegynecologic tract, and combinations thereof. The device 2 can be used toprepare a cardiac annulus and/or the leaflets of a natural heart valvefor open or percutaneous (minimally invasive) valve replacement. Thedevice 2 can expand and deploy a percutaneously delivered heart valve

FIG. 57A illustrates a cross section of a balloon 20 (layers 72 are notshown). The balloon 20 can be in a substantially inflated condition. Thecross section area is shown. The balloon wall 22 can have a balloon wallarea 432.

FIG. 57B illustrates a cross section of balloon 20 in a substantiallydeflated and folded configuration. The balloon 20 is shown in a deliverytube 428 or cannula with a delivery tube inside diameter 436 and adelivery tube inside diameter cross sectional area 434. The balloon 20may be able to slide in the tube.

The compression ratio of the balloon can be from about 3:1 to about10:1, more narrowly from about 5:1 to about 8:1, still more narrowlyabout 6:1 to about 7:1. The compression ratio can be the ratio betweenthe outside diameter 50 of the substantially inflated balloon (e.g., asshown in FIG. 57a ) and the inside diameter of the delivery tube 436(e.g., the tube as shown in FIG. 57B). For instance, a balloon 20 withballoon outer diameter 50 equal to 24 mm (0.945 in) may be folded toabout 3.6 mm (0.142 in).

The balloon can have a packing density equal to or greater than about40%, more narrowly greater than or equal to about 55%, yet more narrowlyequal to or greater than about 70%. The packing density can be thepercentage ratio between the cross sectional area 432 of the walls ofthe balloon and the delivery tube inside diameter cross sectional area434.

The packing density and compression ratios for the balloon can remainsubstantially constant and the wall strength of the balloon can remainsubstantially constant with repeated packing and unpackings, and/orcompressings and uncompressings.

The balloon can be folded into the cannula and expanded about eighttimes or more while not significantly degrading the strength of theballoon wall.

FIG. 58 illustrates that the diametric elasticity of existing medicalinflatable devices can be approximately 0.06 in./ATM and a typical burstpressure is about 3 atm. The medical inflatable device 2 can have anexemplary diametric elasticity of 0.0004 in./ATM and a burst pressureabove 20 atm. Medical inflatable device 2 and balloon 20 can besubstantially inelastic.

FIG. 59 illustrates that the inflation system 470 can be attachable to asyringe 472 or other source of flow and pressure. The inflation system470 can include part or all of the hollow shaft 2000, an inner shaft 477a, a stiffening shaft 476, a hollow shaft lumen 154, a stiffening shaftlumen 478, an inflation port 482 and a stiffening rod control 480. Thedistal end of the stiffening shaft 476 can have a stiffening rod tip484.

The syringe 472 can be detachable or non-detachable from the remainderof the inflation system 470. The balloon 20 may be inflated by pushinginflation fluid, such as water or dye, from the syringe 472, into theinflation port 482, through the hollow shaft lumen 154 and into theballoon 20. The removable stiffening shaft 476 may be left in place tostiffen the inflation system 470 while positioning the balloon 20 in thebody. Once the balloon 20 is in place, the removable shaft stiffener 476can be removed to allow the hollow shaft 2000 additional freedom ofmotion outside the body.

The stiffening shaft 476 can be integral with or removably attached tothe stiffening rod 474. The stiffening rod tip 484 can have atraumaticgeometry, or a soft plastic or elastomeric tip that will minimizepuncture or damage the distal end of the balloon. The stiffener 476 canbe withdrawn manually automatically.

A flexible tether (not shown) may be attached near or at where balloon20 bonds to hollow shaft 2000. The flexible tether may pass thru theinside of hollow shaft 2000 and be anchored to the proximal end ofhollow shaft 2000. The flexible tether may act as a safety strap. Thesafety strap may act as an emergency retrieval tool in case the balloonbecomes detached in the patient. The flexible tether may be made of oneor more of the materials listed in FIG. 28.

FIG. 60 shows that inflation fluid may be provided by detachable syringe472 thru catheter Y-fitting 634. Inflation fluid may flow between in theinside wall of the outer catheter tube 2000 a and the outside wall ofthe inner catheter tube 2000 b. Inflation fluid may flow into balloonvolume 24 to inflate the balloon. A guide wire may be inserted atguidewire port 632 and pass thru the inside of the inner catheter tube630.

FIG. 61 shows a cross section of the heart 562. The heart 562 has anaorta 568, a left ventricle 570 and an aortic valve 564

FIG. 62A shows a folded balloon 20 with a prosthetic heart valve 626crimped over it. In FIG. 62B expansion of balloon 20 from a deflatedstate to an inflated state may cause prosthetic heart valve 626 todeploy to a larger size. Balloon 20 may be substantially non-compliantas described herein. Non-compliance may allow the heart valve to deployto a very precise inner diameter regardless of pressure applied.

FIGS. 63A, 63B and 63C illustrate that a guidewire 572 can be insertedthrough the aorta 568 and positioned in the left ventricle 570 of theheart 562. The device 2 can be slidably inserted over the guidewirethrough the aorta 568. The device 2 may be in a deflated state whenfirst placed in the aortic valve 564. The device 2 can be positioned toalign along the guidewire the balloon 20 with the aortic valve leaflets566. The device 2 can also be rotated about the balloon longitudinalaxis to align with the aortic valve 564, for example when cutting apartattached leaflets 566 in a bicuspid aortic valve with a flange, vane,blade, other cutting element described herein, or combinations thereof.

FIG. 63D shows the balloon 20 in an expanded configuration. The device20 can be non-compliant and open the aortic valve 564 to a precisedimension (for example, about 20 mm (0.787 in) or about 24 mm (0.945in)). The balloon 20 can fixedly reconfigure and press the aortic valveleaflets 566 against the outer wall or annulus 582 of the aortic valve564. The balloon 20 can radially expand the aortic valve annulus 582.

The balloon can have an annular lumen 160, as shown in FIGS. 16 through20. Natural blood flow through the aortic valve can flow through theannular lumen 160 when the balloon 20 is in an inflated or expandedconfiguration in the aortic valve. The device can have a device valve178. The device valve 178 can open and close, for example depending onthe ventricular pressure against the device valve.

FIG. 63E illustrates that the balloon 20 can be deflated, contracted andwithdrawn from the aortic valve 564.

FIG. 63F shows the aortic valve 564 in an opened configuration at alarger dimension than before the procedure.

The method described supra can be performed on an aortic, mitral,pulmonary, tricuspid or vascular valve.

Referring now to FIGS. 64A-64F, The balloon 20 can be used to deploy aprosthetic valve 626 in, for instance, the aortic valve 564 near thecoronary ostia 583. A guidewire 572 may first be introduced thru theaorta 568 into the left ventricle 570. Next, as shown in FIG. 64B, aballoon catheter carrying prosthetic heart valve 626 and deflatedballoon 20 may be introduced over guidewire 572 into aortic valve 564.In FIG. 64C, balloon 20 is quickly inflated to expand the prostheticheart valve into the aortic valve 564. The inflation is performedquickly as, when balloon 20 is fully inflated, cardiac output may bezero. If a balloon 20 with an annular lumen 160 is used (not shown),blood may continue to flow from the heart 562 and into the aorta 568even with the balloon expanded and balloon inflation and deflation maynot be quick. In FIG. 64D, the balloon is quickly deflated, leaving thevalve prosthesis 626 behind in the aortic valve. FIG. 64E show theprosthetic valve closing (64E) and opening (64F) immediately after theballoon 20 is withdrawn

FIG. 65A illustrates that the balloon can be positioned in a narrowed,atherosclerotic length of a blood vessel 574 having atheroscleroticplaque 576 on the interior of the vessel wall 578. The vessel 574 canhave a vessel lumen 580 through which blood can flow.

FIG. 65B illustrates that the balloon 20 can be inflated and expanded.The balloon 20 can remodel the vessel, pushing the sclerotic plaque 576radially away from the balloon longitudinal axis. The balloon 20 candeploy a vascular stent to the sclerotic length of the vessel.

FIG. 65C illustrates that the balloon 20 can be deflated, contracted andremoved from the narrowed length of the vessel 574. The vessel lumen 574can remain patent after the balloon is removed, for example restoringblood flow past the treated atherosclerotic length.

The balloon 20 can be implanted in the body semi-permanently orpermanently. The balloon 20 can have one, two or more openings for fluidentry and/or exit.

Any elements described herein as singular can be pluralized (i.e.,anything described as “one” can be more than one), and plural elementscan be used individually. Characteristics disclosed of a singlevariation of an element, the device, the methods, or combinationsthereof can be used or apply for other variations, for example,dimensions, burst pressures, shapes, materials, or combinations thereof.Any species element of a genus element can have the characteristics orelements of any other species element of that genus. The term“comprising” is not meant to be limiting. The above-describedconfigurations, elements or complete assemblies and methods and theirelements for carrying out the invention, and variations of aspects ofthe invention can be combined and modified with each other in anycombination.

We claim:
 1. A medical balloon, comprising: a base layer; an inner hoopfiber layer over the base layer; and an outer longitudinal fiber layerover the inner hoop fiber layer, the outer longitudinal fiber layercomprising a plurality of spaced apart longitudinal monofilaments. 2.The medical balloon of claim 1, further including an outer layer overthe outer longitudinal fiber layer.
 3. The medical balloon of claim 1,wherein the base layer comprises a polymer film.
 4. The medical balloonof claim 1, wherein the hoop fiber layer comprises a plurality of windsof a hoop fiber.
 5. The medical balloon of claim 4, further including aplurality of outer longitudinal fibers in the outer longitudinal fiberlayer, each outer longitudinal fiber overlying the plurality of winds ofthe hoop fiber.